What 99 owners told NHTSA about the 2016 Mazda Cx-90 Phev

A strong coolant smell was noticed in the interior of the car and from the engine compartment. The diagnosis from the Mazda service facility was that there was coolant leaking from the head on the engine. Eventually this would have led to overheating of the vehicle which could have resulted in significant engine damage. The manufacturer has issued a technical service bulletin (TSB) for this problem. Cracking of the head that leads to coolant leaks is a known problem with this engine in several different models of Mazda including CX-5, CX-9, and Mazda 6. Our vehicle has remained in the shop since it was taken in on 11/8/2022.

NHTSA ODI 11493144

Due to Mazda's known problem in the design of their engine at just over 80,000 miles the head and turbo of my engine have cracked. They have issued a service bulletin to their dealerships, which acknowledges this as a common problem. (Technical Service Bulletins (TSBs) are official communications between Mazda & its dealerships that describe processes for troubleshooting or fixing certain common problems.) Unfortunately, for most Mazda CX-9 owners this bulletin was issued after most have just passed their 60,000-mile warranty, thus allowing them to get away with designing an engine for a fairly expensive car that is only good for 80,000 miles. Mazda further acknowledges this as a problem as newer engines are no longer designed the same way to avoid the problem and any parts put on the engines that are failing are of the new design because the OEM parts will just fail again. Dealing with Mazda customer service is a joke, they are rude, refuse to answer questions and will not call you back with answers when they say they will.

NHTSA ODI 11490103

The cylinder head has cracked and it leaks antifreeze. This can cause the vehicle to overheat and destroy the engine. It is apparently a known issue as Mazda has issued 3 technical service bulletins addressing the problem. They have even redesigned a new part to replace the faulty one. In the TSB they even address that the crack may be caused by "stress generated during production" In other words, its a known problem yet they havent issued a recall on it. Im guessing they havent issued a recall because the quote for the repair was $5000. At $5000 to repair the faulty part it would be quite the expensive recall for the company.

NHTSA ODI 11484450

My Engine is over heading because it has a crack and losing coolant externally. There are 74773 mills on my car. Every 3 weeks I have to put a gallon of coolant in the engine. if I don't put coolant, the engine can stop working on the freeway causing bodily injury to me and other drivers.

NHTSA ODI 11483237

Intermittent Airbag Warning Light (Code 18), Passenger Airbag Deactivation light not operating and no warning chime indicating unbuckled passenger side seat belt. The safety issue appears to be related to the airbag and related safety equipment. In the dash, within the speed and rpm display, the red airbag warning light is blinking, reporting from what I gather is a CODE18, as it blinks once, followed by a pause, followed by eight blinks. It appears to be linked an inoperable PAD warning light, which should be on while no one is sitting in the passenger seat and off while someone is sitting on the passenger seat. While the car is running and a passenger sits unbuckled on the passenger seat there is no warning chime indicating that this passenger is unbuckled. Thank you

NHTSA ODI 11481519

Engine Coolant Leaking from rear of engine near Exhaust / turbocharger at Cylinder Head. No Warning Lights indicating problem until coolant level low causing overheating and fire risk. Rear Brakes not releasing completely from "City Mode" where brakes are kept close to rotor "to increase braking response in City driving" - causes premature brake wear, warped brake rotors (reoccurs within 10K miles from new / replaced rotors) Front Bumper Fascia keeps coming loose at clips near headlights on both Driver and passenger side. Had replaced at dealership 3 times, but continues. Bumper coming loose and can obstruct headlights while moving around at highway speeds

NHTSA ODI 11480443

The clips on both my rear molding over the tires have broken causing the molding/trim to fall off while I have been driving

NHTSA ODI 11480459

Rear wheel trim partially detached from car while driving, safety risk of large plastic part being caught in rear wheel. Did not hit any debris but heard a loud noise as the part detached. Part is supposed to be held in place by 12 clips but multiple owners of Mazda CX-5 and CX-9 models report this problem. Mazda dealers deny there is a problem even when some new cars have only 3 clips installed. When I called Mazda USA to report, and asked them specifically for a federal government contact to report safety issues, they said calling them was the ONLY way to report an issue, which was not correct. Was told I would have to pay for the repair of this safety issue. See this website for the experience of other owners and a description of the problem: https://mazdas247.com/forum/t/2016-cx-9-wheel-well-trim-became-detached.123861160/ I also personally know another Mazda owner who had the same issue with the part falling off while driving.

NHTSA ODI 11477840

2016 cx9, after reviewing online. Known issue with coolent and engine cylinder. Water coolent leak to engine head. Dealer asking 75k to replace engine. Mazda refused to acknowledge the known issue.

NHTSA ODI 11477027

On 04/21/22, I took my car to the dealer after noticing antifreeze on our garage floor and a burning smell. NO check engine lights had illuminated. They proceeded to tell me that there was a coolant leak from head/block and cavity leak (something about channel pressure). They also stated this was a casting flaw during manufacturing of the engine. They told me I needed a whole new engine for $8,479.97! Mazda corporate refused to replace the engine at their cost because I had 64,575 miles on it and it was out of powertrain warranty. I called them and asked to speak to a supervisor and never heard from them. I called on 4/26, 4/27, 4/28, 5/4, 5/5 (5 times), 6/9, & 6/20. I finally gave up agreed to pay $7,479.97 (the dealer gave me $1,000 off). I received the car back on 05/20 and it would not start later that day. They towed it back to Mazda and they replaced the crankshaft sensor that was damaged upon install of the new engine. I received it back again on 05/31 and later in the day, the check engine light came on and the automatic braking system engaged while I was driving (thankfully only 40 mph). I managed to pull over in a turn lane before the engine died. I was so thankful I did not make it onto the interstate I was about to enter! Mazda came and picked me up and later got my car. They could not figure out why it was dying and finally got it to recreate it. They replaced another engine sensor and then drove it a lot to make sure it was truly fixed. I finally received my vehicle back on 07/07. I am afraid to take my car out of town and it makes me nervous it will die and automatically start braking again. They KNOW this is a manufacturer issue and they refuse to take responsibility. I am so disappointed in them. This is a huge safety issue. I am also lucky I didn't blow a head gasket before I took it into the shop the first time.

NHTSA ODI 11474135

Our head gasket is needing to be replaced and sounds like this is an apparent Mazda problem how wide spread it is. The cost is over $5,000 for this single repair, possibly over $6,000 if head is cracked. I only have a parts list showing $1,700 in parts. Service manager said about 18 hours at $189hr totalling $3,402.

NHTSA ODI 11474200

Traveling on the highway going on a road trip. Had vehicle inspected prior and no fuel system problems were noted. I was going 75mph with my family when there was a coasting feeling in the car. I looked and my check engine light popped on and my car immediately would not accelerate and we quickly lost speed. By the grace of God were we able to pull over safely! Code P0132 was the engine code and after an hour, the engine light went back off and we were able to keep a safe speed traveling home. After speaking with a mechanic and dealership, I learned that this was a common problem with the Denso fuel system. My vehicle was not included in a recent recall that included a different year of my vehicle. If manufacturers are aware that a major defect is out there, how many people have to have an accident or potentially cause a huge accident because a car made 2 years prior with the same part from the same manufacturer has the same dangerous problem? It’s ridiculous and I hope you look at this near fatal issue that has effected thousands of people, whose vehicles’ were made in 2017, 2016, 2015 and are not included in the recall.

NHTSA ODI 11472060

I droved my 2016 cx-9 off highway and idled it at front of restaurant, suddenly the engine coolant overheat light came on, shut engine off and found leaking coolant on the ground near the rear of engine bay. Brought the car to Corpus Christi Mazda, found out leaks come from cylinder head crack, happens to cx-9 manufactured before June 20, 2020 according to Mazda TSB 01-013/21. I was quoted $3380 to replace the cylinder head out of pocket because the car is just out of powertrain warranty. I contacted Mazda headquarter for covering the cost out of goodwill since this is due to manufacture defects of cylinder head. Mazda refused to pay.

NHTSA ODI 11470452

I have noticed cracks on both sides of the front bumper on my 2016 Mazda CX-9. Mazda has issued a TSB 09-022-20-3720, however, the cracks recently appeared and my car is no longer under the manufacturer's warranty.

NHTSA ODI 11468688

Cracked cylinder head due to manufacturing defect, left stranded at car wash with no engine coolant due to issue, took several months without a vehicle before it was replaced by Mazda. The vehicle has been repaired. I was left unable to drive in hot weather and could not use air conditioning while waiting for assistance. Dealer had seen the issue before, reported by many on online Mazda forums. There were no warning lamps prior to the incident happening.

NHTSA ODI 11468721

Purchased the car used with 67k miles on it. Within 2 weeks of purchase warning lights went off saying that the engine was overheating due to censor malfunction. After three visits to mechanics (2 to the dealership and 1 to a private mechanic) it was determined that coolant was leaking into the engine causing the engine block to crack. This of course means that the engine will have to be replaced in order for it to be useable. That repair has been quoted by the dealership as a $14,000 repair. For a car that has less than 70k miles.

NHTSA ODI 11467927

15 minutes after getting a wheel bearing replaced at the dealer, my engine coolant high temperature warning came on (never before seen). This occurred while I was on the interstate with no safe place to stop. When I was able to safely stop, I called the dealer. They said bring it back. I was unwilling to drive that far so chose the closest Mazda dealer. They informed me I have a cracked cylinder and the coolant is leaking into exhaust system. I was told the only option due to the mileage on the car (134,000) is to replace the engine for $8,000. This appears to be a known issue so I am shocked that it wasn't being checked for prior to the problem.

NHTSA ODI 11465133

Cylinder head cracked, leaking coolant and causing engine overheated , potential fire hazard . Coolant also leaked and mixed in with oil cycling through engine , causing permanent damage to the engine , resulting engine to be fully replaced

NHTSA ODI 11464797

Dealer diagnosed manufacturing defect that caused crack in head. {Which could lead to engine failure, and subsequent accident due to engine failure during operation.} Engine lost coolant. No overheating noted. No warning/error codes noted.

NHTSA ODI 11445688

The contact owns a 2016 Mazda CX-9. The contact stated that while driving at an undisclosed speed, the air conditioning became warm and the fan was abnormally loud. Additionally, the engine temperature gauge was high. The contact pulled over and refilled the coolant reservoir. The vehicle was taken to an independent mechanic who initially diagnosed that the water pump was faulty and needed to be replaced. However, when the contact took the vehicle back to the independent mechanic for the water pump replacement, the mechanic diagnosed that the cylinder head was warped and referred her to the dealer. The vehicle was not repaired. The dealer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The manufacturer was made aware of the failure and informed the contact that there was no recall associated with the VIN and referred the contact to file a complaint with the NHTSA. The failure mileage was approximately 120,000.

NHTSA ODI 11439847

Brake Booster damaged. I ended up with no brakes and nearly crashed.

NHTSA ODI 11435767

P 255 / 50 R 20 104V M+S tread physically detached while driving at 70MPH Was able to steer and stop the vehicle and avoid a crash, partially due to fewer traffic on the road and the tire in question was on the rear driver side. Was able to replace the tire with my insurance. However no intimation about the failure was mentioned or no further action taken about safety of other tires previously on the vehicle The incident took place suddenly with a huge noise due to the broken tire hitting the wheel well and ripping off the fender. The accident happened on 17th Apr 2019 A supporting link referring a similar incident to a with different model year and date code https://static.nhtsa.gov/odi/rcl/2019/RCAK-19V770-4232.pdf Makes/Models/Model Years: MAZDA/CX-9/2019 Mfr's Report Date: October 28, 2019 NHTSA Campaign Number: 19V-770 Components: TIRES:TREAD/BELT Potential Number of Units Affected: 146 Mazda's number for this recall is 4019J

NHTSA ODI 11433742

I HEARD A PINGING SOUND COMING FROM ONE OF THE WHEELS. WHEN I GOT OUT AND LOOKED, I DISCOVERED THE WHEELS ARE BEGINNING TO FLAKE AND DEGRADE. I CONTACTED MAZDA CUSTOMER SERVICE AND WAS TOLD I WOULD HAVE TO COVER THE COST OF REPLACEMENT AS THE VEHICLE IS OUT OF WARRANTY.

NHTSA ODI 11412830

- THE CAR WAS PURCHASED NEW FROM A MAZDA DEALER IN MAY 2017 - THE DRIVER SIDE CUSHION HEATER FAILED IN MARCH 2020. - THE PASSENGER SIDE CUSHION HEATER FAILED IN NOVEMBER 2020 - BOTH SIDES EXHIBITED THE SAME PROBLEM DESPITE THE FACT THAT THE USAGE OF THE PASSENGER SIDE WAS ABOUT 25% OF THE DRIVER - FROM THE TIME THE CUSHION HEATERS FAILED, WE OBSERVED RANDOM OVERHEATING OF THE BACK HEATERS AND RECORDED "HOT SPOTS" OF UP TO 149 DEG F (PICTURE ATTACHED) - WHILE THE CUSHION HEATERS DON'T OPERATE, THE BACKS GET TOO HOT FOR OCCUPANTS (ATTACHED PICTURE OF SKIN REACTION) AND AT ONE POINT THE PASSENGER SIDE PARTIALLY MELTED A PLASTIC SHOPPING BAG - MAZDA RESPONDED TO THE COMPLAINT THAT THE CAR WAS OUTSIDE OF THE 3-YEAR WARRANTY (EXPIRED IN MAY 2020) AND THERE WERE NO RELATED RECALLS SO THE COMPANY WAS NOT INTERESTED IN ANY TESTING OR INVESTIGATION OF THE PROBLEM ATTACHED: - PICTURE #1: TEMPERATURE IR READINGS - PICTURE #2: EFFECT OF THE OVERHEATING ON ONE OF THE OCCUPANTS

NHTSA ODI 11396524

MULTIPLE TIMES WHILE DURING INCLEMENT WEATHER, POURING RAIN/SLEET, THE DRIVER'S SIDE WINDSHIELD WIPER BLADE FLEW OFF OF THE CAR - CAUSING A SAFETY ISSUE WITH VISIBILITY. WE HAD TO PULL OVER TO THE SIDE OF THE HIGHWAY AND SWITCH TO THE PASSENGER SIDE'S WIPER BLADE, SO THAT WE COULD GET TO A SAFER PLACE TO BE OUT OF THE WAY OF TRAFFIC. IT WAS NIGHT TIME DURING ONE INCIDENT AND DAYTIME DURING THE OTHER. THE ISSUE SEEMS TO BE THE WAY THE WIPER BLADE ATTACHES TO THE ARM.

NHTSA ODI 11364569