Mazda Recalls Over 100,000 Hybrid SUVs Due to Faulty Fuel Gauge Risk

Mazda North American Operations is initiating a recall affecting more than 104,000 of its mild hybrid electric vehicles, specifically the 2024-2025 Mazda CX-90 and the 2025 Mazda CX-70. According to the company’s submission to the National Highway Traffic Safety Administration (NHTSA), a defect in the fuel gauge system may cause it to display an inaccurate fuel level, even when the tank is empty. This issue could lead to drivers running out of fuel while operating the vehicle, potentially resulting in engine stalls and an increased risk of a crash.

The recall encompasses 88,798 units of the 2024-2025 Mazda CX-90 and 16,056 units of the 2025 Mazda CX-70, all manufactured in Japan between December 2022 and April 2025. The root cause of the problem has been identified as a reaction between fuel containing ethanol and the materials on the sub-tank sending unit’s circuit board. Over time, this reaction can create a buildup that interferes with the fuel gauge’s ability to accurately measure the fuel level, leading to erroneous readings on the instrument cluster. No warning lights or indicators are provided to alert drivers to this potential malfunction.

The issue first came to Mazda’s attention in August 2023, when the company received a field report from the U.S. market detailing an engine stall occurring despite the fuel gauge indicating remaining fuel. Subsequent investigations, which spanned over a year and included detailed analysis of chemical reactions influenced by internal fuel tank temperatures, helped pinpoint the ethanol-related interaction with the sending unit circuit board as the primary cause. These investigations also revealed that the problem appeared to be specific to the U.S. and Canadian markets, likely due to varying fuel compositions and operating conditions.

Mazda has developed a remedy that involves reprogramming the vehicle’s Body Control Module (BCM) with updated software. This software enhancement is designed to improve the accuracy and reliability of the fuel gauge’s readings across a wider range of operating conditions. The manufacturing process for the affected vehicles was updated with this improved software on April 25, 2025, at the Mazda Motor Corporation assembly plant in Japan.

Owners of the affected vehicles will be notified by mail and instructed to bring their cars to a Mazda dealer for the free software update. Mazda anticipates notifying dealers by September 5, 2025, and expects to mail owner notification letters by November 1, 2025. The company is not offering reimbursement for any related costs, as all affected vehicles are reportedly covered under full warranty. As of the recall submission date, Mazda stated it was not aware of any accidents or injuries associated with this defect. Vehicle identification numbers (VINs) will be searchable for recall status beginning September 5, 2025.

Article by Mel Anara, based upon information from Mazda North American Operations

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