Mazda CX-90 engine problems

ENGINE

Istop engine malfunction Msp66, 2nd time occurring after recall fix

NHTSA complaint #11757228 — an unverified report by a vehicle owner.

ENGINE

I leased that car Mazda cx-90 from Mazda of [XXX] [XXX] Since i got the car i had feeling the steering wheel its not normal, also the water its under normal level when i did the oil change and the maintenance i mentioned all the issues i have but they didn’t do anything till the last time when they did the oul change the inform me that i have to replace the steering wheel gear and the RADIATOR for $4000 they said its not under the coverage anymore over 36000 miles, and they didn’t say anything about what i have told them before ! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11755566 — an unverified report by a vehicle owner.

ENGINE

I am reporting a recurring safety-related issue with my 2024 Mazda CX-90 Turbo S Premium involving the mild hybrid system. The first failure occurred at approximately 28,000 miles. While driving, the vehicle displayed multiple warning messages, including "Mild Hybrid Battery Malfunction," "i-Stop Malfunction," and "Engine Malfunction." Shortly afterward, the vehicle entered a reduced-power (limp mode) condition. The loss of normal power made it difficult to safely accelerate and keep pace with surrounding traffic, creating a significant safety concern. The dealership diagnosed the vehicle and replaced the mild hybrid battery. My vehicle remained out of service for approximately one month while repairs were completed. At approximately 56,000–58,000 miles, the same problem occurred again. The vehicle once again displayed the "Mild Hybrid Battery Malfunction," "i-Stop Malfunction," and "Engine Malfunction" warning messages and again entered reduced-power mode while driving. The repeated loss of power created another serious safety concern because the vehicle could not accelerate normally when merging into traffic or driving on higher-speed roads. After diagnosing the second failure, the dealership informed me that, in addition to replacing the mild hybrid battery, corrosion had been found in the wiring harness and internal wiring associated with the hybrid battery system. Those components also required replacement. Due to parts availability, my vehicle remained at the dealership for an extended period before repairs could be completed. This vehicle has experienced the same hybrid system failure twice within approximately 58,000 miles, despite the first battery having already been replaced. I am concerned that this is a recurring defect affecting the mild hybrid electrical system. A failure that causes multiple system malfunction warnings and forces the vehicle into reduced-power mode while driving increases the risk of a crash, especially when merging onto highways

NHTSA complaint #11755124 — an unverified report by a vehicle owner.

ENGINE

At just under 40,000 miles, the radiator started leaking along the seams. It was noticed by the dealer repair shop when the dealer was performing warranty repairs on the front differential. There were no other indications before discovery.

NHTSA complaint #11752519 — an unverified report by a vehicle owner.

ENGINE

I own a 2026 Mazda CX-90 hybrid with approximately 13,000 miles. The vehicle began making a grinding noise while driving, which has progressively worsened over time. It has since developed a hard knocking noise accompanied by noticeable vibration when the vehicle shifts gears. This knocking occurs during normal in-town driving. I have taken the vehicle to the selling/authorized Mazda dealership on two occasions — June 2, 2026 and July 14, 2026. On both visits, the dealer was able to reproduce and confirm the noise and knocking. The dealer stated they are aware other customers have reported the same issue, but that Mazda considers the noise/knocking acceptable and declined to perform a repair. No warning lights or diagnostic trouble codes have appeared at any point; the only symptoms are audible and physical. The vehicle is under both factory warranty and a purchased service/maintenance agreement. It has only been inspected by the selling dealership; no inspection has been performed directly by Mazda North America, law enforcement, or an insurance representative. I am concerned about my safety and the safety of others because a worsening, unexplained drivetrain issue that produces hard knocking and vibration during routine driving suggests a mechanical fault that could progress to sudden failure, and the manufacturer has declined to investigate or repair it further despite the symptom escalating across two documented visits. The vehicle remains available for inspection upon request.

NHTSA complaint #11750408 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2024 Mazda CX-90. The contact stated that while operating the vehicle, several warning messages were displayed on the instrument panel, including the electronic stability control and the check engine warning lights. Later, while driving, the power steering failed, causing the steering wheel to become difficult to turn in either direction. The vehicle was driven to a local dealer, who was unable to determine the cause of the failures. The contact was informed that the battery would not remain charged. The manufacturer was not yet contacted. The failure mileage was 29,000.

NHTSA complaint #11749351 — an unverified report by a vehicle owner.

ENGINE

While the car was being repaired for the rear brakes issue that was covered under the recently announced extended warranties, the Mazda dealership stated there is also a radiator leak that should be repaired for $1,800. After researching online, it didn't take long to learn that this is another known issue with Mazda CX90s but hasn't been formally recalled at this point. I have no complaints with the dealership I purchased the vehicle from. The complaint is with the manufacturer for yet another known issue on the CX90s that is not a normal maintenance for a 2-3 year old vehicle.

NHTSA complaint #11748299 — an unverified report by a vehicle owner.

ENGINE

There was a recall issued within the last year for my make and model vehicle, in March 2026, it was fixed when my car was towed to a Mazda dealership due to a check engine light and "hybrid engine malfunction". On June 24, 2026, the vehicle went into limp mode, the error message resolved upon turning off the vehicle. There were no check engine lights that appeared. On June 25, 2026, the vehicle went into limp mode on I-5 in traffic. We were able to safely get the vehicle to a safe location out of traffic. The error code on dash was "hybrid engine malfunction" again. The radiator was replaced at a second Mazda dealership, we were told "that should fix the problem". There was no indication the radiator needed replaced due to no fluids leaking and no overheating of the vehicle. The battery did fail during this visit. On June 26, 2026, when we were on I-90 in traffic again, the vehicle went into limp mode again with the same hybrid engine malfunction warning. The vehicle was towed to a third Mazda dealership to finally have the hybrid battery finally replaced. The only warnings were when we went into limp mode, no dash lights or check engine lights, nor overheating. The safety of my family was put at risk due to the vehicle decelerating from 75 mph to 35 mph in the fast lane of traffic twice. Mazda has done all service repairs and recalls.

NHTSA complaint #11747320 — an unverified report by a vehicle owner.

ENGINE

Over my time owning this vehicle i have had several different safety concerns. although they have been resolved by the dealer, i have concerns for anyone purchasing this make and model. 1. lane departure. i have turned off lane detection because i have had the car try to auto correct and jerk me to the left into oncoming traffic 2. i have had incidents where the driver door was unable to be opened from inside. i had to roll down the window to open the door and get out 3. At a speed of 45mph, the vehicle suddenly went into limp mode. the car turned off and luckily i was able to pull over into a safe area. again i experienced the door locking from the inside. all issues and solutions have been documented at dealer services. these issues are of great concern and potentially could have been harmful or fatal. i no longer have trust in this model or company.

NHTSA complaint #11747146 — an unverified report by a vehicle owner.

ENGINE

Vehicle radiator cracked at 31k miles on the highway leaving myself and my family stranded. My roof has been leaking since I bought the vehicle and Mazda keeps saying they can't replicate the issue and if I can find it they will then fix it. I don't think that's my job. I bought a car that I expected to be able to drive safely without issues. I don't want to play find the issue because I'm not a mechanic or manufacturer. It has been in and out of the shop since purchase in October 2023. Longest period was about 28 days. It's currently in the shop for the radiator and many people are having the same issue. They say I am 3 weeks past warranty but with these items being known issue I don't want to have to pay for them.

NHTSA complaint #11742001 — an unverified report by a vehicle owner.

ENGINE

My 2024 Mazda CX-90 MHEV has experienced multiple life-threatening sudden engine stalls and a complete loss of motive power while driving in active traffic lanes. The first incident occurred on December 31, 2024, when the vehicle abruptly shut down with an "Engine Malfunction" dashboard alert. The vehicle was towed to an authorized Mazda dealership (Palatine, IL), where it was held for a week, but technicians stated they could not replicate the issue and returned the car to me as safe. On March 30, 2026, the exact same failure recurred. While driving, the engine suddenly shut off completely at a traffic intersection. After turning the vehicle off for 5 minutes, it was restarted and driven to another authorized Mazda dealership (Crystal Lake, IL) for specialized diagnostic scanning. The second dealership successfully retrieved stored diagnostic trouble code (DTC) P061B, which is directly linked to safety recall 24V-815 (Loss of Drive Power from Software Errors). Crucially, the detailed diagnostic scan revealed that this code was historically stored with a timestamp dating back to December 2024. This proves that the safety defect was active and detectable during the first dealer visit 16 months prior, but was completely missed by the first dealership, leaving my family with an ongoing crash hazard. To address the failure, the dealership replaced the low-pressure fuel pump in the fuel tank and a mass airflow (MAF) sensor. However, Mazda Corporate customer experience has formally stated to me in writing that they are "not in a position to guarantee the concern will not reoccur." Because this safety-critical propulsion failure causes the vehicle to suddenly die in traffic and has a documented history of ineffective recall remediation, it poses an unresolved, severe crash risk. The vehicle is currently in my possession and available for inspection.

NHTSA complaint #11737446 — an unverified report by a vehicle owner.

ENGINE

The vehicle experienced a sudden and repeated malfunction of the hybrid/electrical system and powertrain, resulting in the vehicle becoming inoperable. The vehicle is currently at the dealership and is available for inspection upon request. While driving in traffic, multiple warning messages appeared, including "Hybrid System Malfunction," "Charging System Malfunction," "Engine Malfunction," "Brake" and "i-ACTIVSENSE System Malfunction." The vehicle lost functionality and could not operate normally, creating a dangerous situation in active traffic. I was forced to slowly maneuver the vehicle to the shoulder after several restart attempts. This issue has been reproduced multiple times. The vehicle has previously been inspected and repaired by an authorized dealership, including recent repairs (12V battery and engine mounts). Despite these repairs, the same critical malfunction occurred again shortly after the vehicle was returned as repaired. The vehicle is currently being inspected again by the dealership. The issue has not yet been permanently resolved. Prior to the failure, the vehicle had a history of similar warning messages and abnormal behavior beginning at approximately 20,000 miles. These issues have continued intermittently despite multiple repair attempts. The repeated failures, including the most recent incident, indicate an ongoing unresolved defect that creates a significant safety concern. This issue is a continuation of a previously reported complaint (NHTSA Report No. 11734505).

NHTSA complaint #11736989 — an unverified report by a vehicle owner.

ENGINE

The car thinks the key fob is inside the vehicle when it is not. If you get out of the vehicle it will not self lock even if you have that feature set up. It will also beep consistently for about 10 seconds when you press the lock button on the key fob when your outside of the car, indicating that there is a key fob in the car....but there is not. The most concerning thing is you can get into the car and start it without any key fob inside the vehicle. It always thinks the key fob is in it, at all the time and will start without any key fob in it. This is not an occasional thing. It has been like this since we pirchased it from Mazda as a CPO vehicle. It's been doing this for all 2 months that we've owned it. We currently have an appointment with the dealership to take it in for them to hopefully fix it as well as other issues.

NHTSA complaint #11737085 — an unverified report by a vehicle owner.

ENGINE

When turning on the heater or AC, the car blows out a coolant smell out of the vents. It does it every time the heat is turned on or switched over to AC. We have another appointment with the dealership to have this looked at, as well as many other issues we're having with this vehicle.

NHTSA complaint #11737090 — an unverified report by a vehicle owner.

ENGINE

This issue I’ve seen on different forums just happened to me. Lower radiator hose leaking. Car is at 37000 miles and under no circumstance should this be happening to a new vehicle, Mazda has known about the issue apparently in my model year the manufacturing over tighted the clamp causing it to fail prematurely. This can be catastrophic especially since these leaks are just waiting to happen. If someone was on the highway it would be dangerous

NHTSA complaint #11735826 — an unverified report by a vehicle owner.

ENGINE

Radiator leaking at seems causing engine to overheat. The radiators on 2024 and earlier CX-90 are failing at the seems of the radiator. This is a known issue to Mazda, hundreds of vehicles are having to be repaired for this manufacturing defect and they are charging the consumer $2800.00 to repair something which should be covered under a recall. This vehicle is a lemon and they refuse to stand behind their product.

NHTSA complaint #11733664 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2024 Mazda CX-90. The contact was informed about a previous recall associated with the steering that was repaired prior to owning the vehicle, but the failure persisted. The contact stated that while driving on several occasions at various speeds and turning, the steering wheel jerked in the opposite direction, then became soft, and then more difficult to steer. The vehicle was not diagnosed or repaired, but the contact was informed of a steering investigation. On another occasion, the contact stated that when the vehicle was stopped and the ON/OFF feature was activated. There was an abnormal knocking sound coming from the engine compartment. The contact stated that after turning off and restarting the vehicle, and after refueling the vehicle, the messages "Engine Malfunction – Inspect Vehicle" and "Hybrid System Malfunction" was displayed. The check engine warning light was illuminated. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 56,050.

NHTSA complaint #11730780 — an unverified report by a vehicle owner.

ENGINE

We believe the evaporative emissions control system (EVAP) / fuel vapor management system on our 2024 Mazda CX-90 MHEV (inline-6 mild hybrid) is malfunctioning, releasing strong raw gasoline vapors. The strong odor occurs everywhere around the vehicle while the engine is running and immediately after shutdown and exit. The problem is intermittent. No visible liquid fuel leaks have been observed. The vehicle and related components remain available for inspection upon request. This creates a direct safety risk: the hazardous flammable gasoline vapors are strong enough to migrate from our garage into our living space (house), posing a potential fire/explosion hazard if vapors accumulate near an ignition source, as well as a health concern from prolonged inhalation for our family. Raw gasoline vapors are highly flammable and should not be present in or around a residence. The problem has been reproduced and confirmed by the dealer on at least one occasion. On the third service visit (dropped off March 5, 2026), the strong raw gasoline odor was so intense upon arrival that multiple dealership personnel, including General Manager Weldon Munsey, witnessed it immediately, and one technician looked under the vehicle to check for liquid gasoline leaks. On the two prior visits, technicians were unable to replicate the issue. The local dealer has informed us that they are aware of two other CX-90s with the exact same problem occurring at the same time within their dealership network. Despite having no root cause, no fix identified, and no timeline for resolution, the dealer wants us to return the loaner and take our car home unrepaired. The vehicle was purchased new on [XXX], and currently has 39,213 miles. It has been inspected multiple times by the dealership (Roger Beasley Mazda Georgetown, repair order [XXX]). Mazda Corporate has an open investigation (their case [XXX]) and has assigned a case manager (Chris) who is currently reviewing the issue with the service INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATIO

NHTSA complaint #11730940 — an unverified report by a vehicle owner.

ENGINE

Since taking delivery of this vehicle in June 2024 from Kenny Ross Mazda, I have experienced a persistent and unresolved error message on the vehicle’s display screen relating to “Multiple ECUs Reprogramming.” This error message first appeared within the first twelve (12) months of ownership and has remained continuously present on the vehicle’s instrument cluster/infotainment screen despite numerous repair attempts. The defect substantially impairs the use, value, and safety of the vehicle, as it creates constant uncertainty about the operational status of critical electronic control systems, diminishes the vehicle’s resale value, and interferes with my normal use and enjoyment of the vehicle. Photographic evidence of this error message is attached as Enclosures 2 through 5. I have brought the vehicle to Rohrich Mazda, an authorized Mazda dealership and service facility located in Pittsburgh, Pennsylvania, on at least seven (7) separate occasions over the past twelve (12) or more months in an effort to resolve this defect. Each time, the dealership has been unable to eliminate the error message. During the course of these repair attempts, the dealership initially believed the issue was related to a recall (Safety Recall 7024J — Multiple ECU’s Programming), but subsequent repair attempts have failed to resolve the condition. The dealership has contacted Mazda Corporate technical support on multiple occasions, and Mazda Corporate has been unable to provide a solution. As of this writing, the dealership and Mazda Corporate have acknowledged that they do not currently have a fix for this problem. The service ticket remains open.

NHTSA complaint #11730202 — an unverified report by a vehicle owner.

ENGINE

I am submitting this complaint regarding my 2025 Mazda CX-90 PHEV, leased in April 2025. Since early in my lease, the vehicle has had ongoing drivability issues that have worsened over time and now present a serious safety concern.From the beginning, the vehicle exhibited jerking and hesitation while driving. Initially minor, this has become more frequent and now includes stalling behavior during normal driving conditions, including acceleration and traffic flow. This creates a risk of collision, especially when merging or at intersections.Approximately six months into my lease, the radiator failed and had to be replaced. More recently, while driving, multiple warnings appeared at once: Hybrid System Malfunction, Battery System Malfunction, Oil Monitoring Malfunction, and i-ACTIVSENSE partially disabled. These warnings were documented.Two weeks prior, the dealership reported no diagnostic codes. However, on my most recent visit, I was told via video that the active air shutter is now the issue. The required part is on backorder until August. I was told I could either remain in a non-comparable loaner while still making full lease payments, or continue driving the vehicle in its current condition until the part arrives. I find this unacceptable given the safety concerns.I expressed that I do not feel safe driving this vehicle, but the service advisor stated this is “not a safety concern.” I disagree. A vehicle that jerks, hesitates, or stalls while driving, combined with multiple system malfunctions and disabled safety features, presents a clear safety risk.I also disclosed prior to leasing that I do not have access to charging. I was told this would not be an issue. I am now being told that not charging the vehicle may be contributing to the problem. Service advisors have also indicated these vehicles have known hybrid battery issues.I no longer feel safe driving this vehicle and am concerned for my safety and my family’s safety.

NHTSA complaint #11727400 — an unverified report by a vehicle owner.