Recall 16V685 affects 3,849 2016 Mazda MAZDA3 vehicles for a fuel-tank weld leak. Repair is free at any franchised Mazda dealer.
Mazda is recalling 3,849 2016 MAZDA3 vehicles because deformed fuel tanks can leak fuel at the recirculation pipe welded connection. A fuel leak near an ignition source increases the risk of a fire, and Mazda dealers will complete the recall repair free of charge.
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What's wrong?
The fuel tank on the 2016 Mazda MAZDA3 stores gasoline and seals it inside the vehicle's fuel system. It also connects to a recirculation pipe, a tube that routes fuel and vapor back through the tank system instead of letting them escape. That welded connection has to stay tight during normal driving, heat, and vibration.
On affected MAZDA3 vehicles, inadequate control at the tank manufacturing facility deformed the fuel tank before the recirculation pipe was welded on. That distortion left the pipe with an insufficient weld. When the tank is filled and the car is driven, the weak welded area can leak fuel from the connection.
There is no warning sign before failure. An owner should not rely on a dashboard light, sound, or drivability change to catch this defect before the leak starts.
Who's affected?
| 2016 Mazda MAZDA3 | fuel system |
|---|---|
| Units affected | 3,849 |
| Field incidents | NHTSA has logged 1 field incident to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific car.
What's the safety risk?
A fuel leak near an ignition source increases the risk of a fire. Avoid open flames or other ignition sources around the vehicle, and schedule the recall repair soon so the dealer can inspect the fuel tank and replace it if needed. Repair is free at any franchised Mazda dealer.
What should I do?
- Check your VIN to confirm your 2016 Mazda MAZDA3 is included in this recall.
- Contact your nearest franchised Mazda dealer to schedule the free fuel-tank inspection and any needed tank replacement for the recirculation-pipe weld leak.
- Bring the recall notice if Mazda mailed one. If not, reference recall number 16V685 when you call.
- Avoid smoking, open flames, and other ignition sources around the vehicle until the dealer completes the repair.
What happens at the repair
At the dealer, a Mazda technician checks the fuel tank lot number. If that tank lot is covered, the technician inspects the recirculation pipe weld and replaces the fuel tank when the weld condition requires it. The recall repair is free, with parts and labor covered. Mazda has a general reimbursement plan on file for owners who already paid for a related fuel tank or fuel leak repair. Bring repair invoices and payment documentation to the service desk, or contact Mazda customer service for claim instructions.
| Reimbursement | Reimbursement available |
|---|
Timeline
| September 23, 2016 | NHTSA published the recall |
|---|---|
| October 13, 2016 | Dealer notification began |
| October 13, 2016 | Dealer notification ended |
| November 1, 2016 | Interim owner notification (was planned for this date) |
| November 18, 2016 | Owner notification mailed |
Frequently asked questions
What is recall 16V685?
Recall 16V685 covers 3,849 2016 Mazda MAZDA3 vehicles built with fuel tanks that were deformed during manufacturing. The defect can cause a fuel leak at the recirculation pipe welded connection. Mazda dealers will inspect the weld and replace the fuel tank for free when needed.
What should I do if my 2016 Mazda MAZDA3 is on this recall?
Check your VIN to confirm your specific MAZDA3 is included in recall 16V685. If it is, contact a franchised Mazda dealer and ask for the fuel tank inspection under Mazda recall 0216I. The dealer will inspect the recirculation pipe weld and replace the tank for free when required.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. Mazda's remedy says dealers will inspect the recirculation pipe weld and replace the fuel tank as needed, free of charge, at a franchised Mazda dealer.
What is the safety risk?
The safety risk is fire from a fuel leak. Mazda reported that a deformed fuel tank can leak fuel from the recirculation pipe welded connection. If leaking fuel reaches an ignition source, the risk of a fire increases. The dealer repair is free.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V685000 |
|---|---|
| Mazda customer service | 1-800-222-5500 |
| NHTSA recall # | 16V685 |
| NHTSA recall # (full) | 16V685000 |
Source documents
-
Download Recall Investigation Document (PDF) (PDF) - Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →