2024 MAZDA CX-90 Engine Problems

Dear NHTSA Team, I am writing to formally report and follow up on a safety-related issue regarding my 2024 Mazda CX-90 PHEV, VIN: [XXX] . The vehicle has experienced repeated defects affecting critical safety systems, including: Engine overheating and cooling system failures Repeated engine malfunction warnings EVAP/emissions-related system faults These issues have persisted despite multiple visits to authorized Mazda service centers, and no permanent repair has been achieved. The defects raise serious concerns regarding the vehicle’s safety, reliability, and potential risk to road users. I have submitted a complaint via NHTSA’s Vehicle Complaint system but would like to confirm receipt and request the current status of my case, or any guidance on next steps. Please let me know if additional documentation, service records, or details are required. I am fully willing to cooperate to ensure this matter is properly reviewed. Thank you for your attention and assistance. Sincerely, Dr. [XXX] [XXX] Phone: [XXX] Email: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

My new Mazda CX-90 failed to restart after being stopped at a stop sign. After restarting manually, the dash displayed the check engine light and the “i-stop malfunction” light. The car now flashes this warning whenever it is on. There is an open recall for this issue (24V-816) but my local Mazda dealer does not pull anything up when they search my VIN. It appears the recall only applies to these vehicles built between 12/23 and 4/24. My car was built in 11/23. I believe this recall should be expanded to included more vehicles like mine.

I am reporting serious safety concerns with my Mazda CX-90 PHEV (leased, manufactured September 2023). These issues create unacceptable risk to occupants and other road users. Multiple Severe Recalls: My vehicle has had at least four major recalls: • 6323J – Engine & Motor Shutdown: Complete loss of propulsion without warning. • 7024J – ECU Software Failures: Loss of drive power and restart failures. • 24V817000 – EV Mode Power Loss: Sudden propulsion loss in EV mode. • 6724E – Sudden Braking: Automatic braking without cause. These defects could lead to crashes or fatalities. Hybrid System Malfunctions: Two recent “Hybrid System Malfunction” warnings required dealer visits. These failures could cause the car to shut off while driving—even at highway speeds. • First incident: Battery-related issue. • Second incident: Triggered by a loud noise during startup, impacting the AVAS system. A loud noise should never disable a family vehicle, indicating a design flaw. Charging Safety Issues: Charging via a standard outlet caused flickering lights and breaker buzzing in my house. A licensed electrician diagnosed harmonic distortion from the onboard charger. I spent $7,500 on electrical upgrades (dedicated EV line and panel upgrade) to charge safely. Manufacturer Response: I have had an open case with Mazda corporate for nearly two weeks. They refuse to acknowledge overall vehicle safety or provide written documentation confirming safety. Request: I urge NHTSA to investigate whether these defects represent a systemic safety issue in Mazda CX-90 PHEV models and take appropriate regulatory action

i-Stop Malfunction. Engine not restarting after the hybrid system stalls engine at a stop.

Upon starting the vehicle, on the dash there was a message "hybrid system malfunction" as well as "engine malfunction have the vehicle inspected". Upon driving it home, the same message appeared 10/24/25 as of today when the car starts now the only message that remains is "engine malfunction have the vehicle inspected" I have an appointment at Mazda on 10/30/25 for the vehicle to be inspected. This vehicle has already been taken to this location for two recalls. Today 10/26/25 I looked up my vin for any new recalls and there is an additional recall. Manufacturer Recall Number7825I NHTSA Recall Number25V-568 Summary When fuel containing ethanol is used, it may react with materials on the sending unit circuit board in the sub-tank. This reaction can create a buildup that interferes with the gauge function that may cause the display on the instrument cluster to read an incorrect fuel level. Safety Risk If the vehicle incorrectly indicates an inaccurate fuel level, there is a risk of running out of fuel while driving. This would result in an engine stall and the vehicle cannot be restarted, increasing the risk of a crash.

I bought a brand new 2024 CX90 in May 2025. I was on the on-ramp entering a Highway at an accelerating speed when the car all of a sudden went into a limp mode and was unable to accelerate. This limp mode that kicked in almost caused me to be hit from behind. Immediately on the dash it flashed Engine Malfunction. I had to pull over to the side of the highway and had the car brought to my local Mazda Dealer. My local Mazda dealer stated that the recent recall #25V-568 NTSHA caused the program/software for the car to misread my fuel pump and essentially burned out my fuel pump, and therefore breaking my fuel pump. They said they called Mazda, and Mazda is denying the fix because there is "no release date". Since Mazda is refusing to fix this, my local dealer says I have to drive the car as is. However, this is unsafe to drive. I paid for a brand new car only for it to have tech issues with Mazda refusing to do any fixes. This is our family car and I drive around with young kids. This is very unsafe to drive and Mazda needs to remedy this siutation immediately.

My Mazda CX90 consistently has a hard delay before jerking my car forward, especially when shifting between 2nd and 3rd gear. This is most common at slow speeds and accelerating from a stop. On top of generally rough shifting, there have been four separate instances where my car blatantly stopped accelerating and slowed my car from 70-80 mph down to 40-45 mph. Once driving up a hill, and the rest on a flat interstate. I tried flooring the gas each time and the rpms would go up to approx 6000, but the car simply would not respond. After multiple attempts to let off of the gas and re-engage the vehicle, my car suddenly began accelerating again and continued as if nothing happened. I have been able to safely move out of traffic's way each time, but this presents a great threat to myself and others as I have no control over my speed and can easily get into a collision. As if uncontrollable stopping on the freeway isn't enough, my vehicle also accelerates on its own and jolts itself forward when driving at slow speeds through parking lots and stand-still traffic. These accelerations have occurred at idle with the breaks both on and off. The vehicle only propels itself forward by a couple of feet, but the issue seems to be getting more severe each time it occurs. Luckily I have been able to control the car and stop myself from hitting others so far, but I am afraid this may cause harm to pedestrians or people in nearby vehicles. I have mentioned these issues to my local Mazda dealership on multiple occasions, but they dismissed my concerns each time and told me my vehicle is in safe operating conditions. They claim they have not been able to replicate any accelerating/ decelerating instances, and they say the car's shifting is within spec. My car has never thrown any codes or displayed warning lights on the dash. I have taken the vehicle in for all recalls and maintained it well. I recently hit 15000 miles, though these issues have been presenting since 5000.

Engine Malfunction have serviced. At least 3 times. One of the 3 (so called) repairs took 3 weeks. They said “Tariffs you know Japan”. When I get this warning my car engine seems to vibrate. I have only had my car since August of 2024. New vehicle I am the 1st and only owner. Today is June 22, 2025 and tomorrow will be another incident number 5. My car is doing this again. I am a [XXX]. Most of the time my car is in the garage. But I have to drive 188 miles on the turnpike to visit my son and come back. This is every 3 months or so. My other son drove to South Texas. These warnings always came on. Am I supposed to stay home and only go to the store. I pay over 700.00 a month. This is not good. I am now getting afraid to drive it. So tomorrow I will again have to drive to Edmond Oklahoma and have it repaired again. “Engine Malfunction have services”. I’m so disappointed. My son has a cx-5 and it’s a great car. I’ve had so many loaners. They have been fine. I am told this is a brand new model and we have to get the kinks out? This is at my expense, peace of mind. Please help me. Thank you. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I’ve been experiencing power loss and surges/RPMs drop for nearly a month now while driving at various speeds. Each time, the iStop indicator comes on. This is a serious safety concern. I am extremely worried that the vehicle could stall, especially while my family is in the car, while driving on a busy highway. Undoubtedly, this issue presents a significant risk to the safety of drivers and passengers. I am requesting your assistance in initiating an official recall from the manufacturer for this component failure. Based on my research, I am not the only one experiencing this grave issue. Many others have reported similar problems on forums like Reddit, which is proof that this is a widespread issue.

Brought vehicle into Dealer for Service due to Check Engine Light being on and Notification of a Malfunction of the I-Stop System. Service Tech indicates that this is a known issue with the Hybrid Battery in these vehicles that could cause the vehicle to unexpectedly stall. This safety issue is significant enough that they would not let us take our car home while we wait for them to obtain a battery, which are currently on backorder. Pursuant to a conversation with a Mazda Customer Experience Representative this has been a known issue since at least January. We have not received any correspondence from Mazda regarding this issue. It would appear that a Bulletin or Recall is warranted for what appears to be a prevalent issue with significant safety impacts.

The wires under the hood were chewed up by rodents. The cars wires are insulated with a soy based wiring coating. My car is at the dealership for repair and deemed undrivable. This is so unfair because the car is new and only has 6200 miles on it. I am now facing insurance deductible. The dealer says the vehicle is undrivable because it is a safety issue and the engine might catch fire

I’ve only owned this brand new vehicle for just two months. Had I known these issues, I would not have purchased the CX90! Having issue with I-stop causing vehicle to stop whenever and now the dash display just popped up yesterday 12/09/24 regarding “Headlight Malfunction contact dealership”. I contacted the dealership yesterday and was going to be charged for a diagnostic test on a two month old vehicle, I don’t think customers should have to pay for a diagnostic test on a “brand new vehicle” and was also advised, Mazda is aware and working on issue (headlight malfunction has been complained about since 2023) but no recall on headlight malfunction, test! As well as now, there are two campaign #7024 J and #7124 J But at the present time service department is waiting on “when” the recall and headlight issue can be serviced! I’m confused why owning a brand new vehicle and being told of issues and experiencing issue along with recalls and not being able to get them fixed is asinine! What customer wants to pay lots of money on a vehicle to risk injury or damage due to manufacturer dragging their feet. I would appreciate assistance in these issues! Thank you

While driving (less than 2000 miles on the OD) in our 2024 cx90 SE the vehicle started to shift out of timing and everything shut off at once. The vehicle lost all power and all parts shut down. The vehicle would start back up and power steering went out. Our driving speed was at 30mph so it was extremely scary during rush hour traffic. We had to have it towed to the dealership, we're not sure what the issue will be.

The contact owned a 2024 Mazda CX-90. The contact stated while driving 40 MPH, the engine seized. The contact stated that the failure occurred while the contact was driving at night on a busy dark road. The Police was contacted for assistance. The contact stated that it took two days for the vehicle to be towed from the location because the vehicle was missing a tow tool. The vehicle was towed to the dealer where the vehicle was diagnosed with engine failure. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was filed. The contact no longer owns the vehicle, after agreeing to a buyback. The failure mileage was approximately 28,100.

Mileage: 28,100

Vehicle present engine hesitation. In acceleration the engine losses power, noticeable delay and jerk when accelerating from a stop. Also if you have to make a suddenly speed reduction, you see that the vehicle still accelerating. First time the dealership did a technician service bulletin to fixed the problem, but for the second time with exactly the same problem they said that is normal. That’s a safety issue and Mazda is ignoring the concern.

Loss of engine power/acceleration while driving on highway. Was able to safely pull over but felt in danger during the incident especially with cars behind me surprised by my vehicles loss of power.

Stopped at a red light on a busy 2-lane road. I-stop function turned the engine off. When the light turned green, releasing the brake caused a "Hybrid Battery Malfunction" error and the engine failed to start. We put the transmission in park and attempted to turn off and turn on the car with the push to start button. When we attempted to start the car with the push to start button, the car would not start. We were unable to shift into neutral to move the car out of the busy 2-lane highway and were blocking traffic for about an hour. The first tow truck to arrive was unable to move the car onto the flat-bed because the transmission was stuck in park and would not go into neutral so another tow truck was dispatched with a dolly. Our safety was at risk because we were stuck in an immobile car in busy highway traffic. A police officer arrived to help direct traffic around our disabled car. The vehicle is currently at the dealership and has not been inspected as of the time of this report.

On 3 separate instances the car starts to buck, speed dropped from 75mph to 50mg in first instance. Then the engine malfunction light comes on. The engine looses power and will only drive at 30mph. Once pulled over and shut car off and restart, attempt to drive again with zero power from the engine.

On July 15, 2024 this vehicle at 50 mph on cruise control suddenly flashed white warning words indicating problems with the cruise control and immediately thereafter started flashing “hybrid malfunction” and to return to service dealer. At the time of the hybrid malfunction warning which was right after the quick cruise control warning, the engine operation, specifically the gas pedal no longer delivered power to vehicle, either electric or gas. Additional warning was to pull off to the side and stop and turn off vehicle. This occurred and vehicle was pulled to the side put into park and turned off. Waited approximately 3 to 5 minutes and restarted the engine which started in gas with no electric although there was electrical charge on the battery. Was able to continue to our final destination approximately 15 minutes later and no more than 10 miles driven. Hybrid malfunction was still visible on the dash to include the warning stating that vehicle needed to go to the service department. Approximately an hour later, vehicle was turned on again with the same warning about the hybrid malfunction, however, engine started in electric. Drove vehicle to dealership and stated what happened. Dealership the next day stated that this was a phantom code known by Mazda, but no problems associated with the code. Vehicle picked up per service advisors request two days later. Mazda dealership stated that headquarters had eyes on this particular vehicle. A day later after the pick up Mazda dealership requested vehicle be brought back for a “DC box” repair. Dealership stated this process would take a week or thereabouts to replace this component. Vehicle currently in dealership service.

There has been two dangerous failures both occurring in an intersection. First instance was in December of 2023 whey the fuel pump failed while turning in an intersection. The second incident was a hybrid battery malfunction, rendering my vehicle unusable in the middle of an intersection again. This was 03/2023

Car has 5000 miles on it. Numerous issues with car. Unsafe steering. Dealer not able to repair steering until Mazda provides parts for recall. Now on the highway with a medium depressed foot pedal the car speeds up on its own. Happened 2 times so far. Brakes had to be applied to slow car down. It was very brief because I immediately stepped on the brake, but it was definitely an uncommanded acceleration. Both times I did NOT have cruise control on. Definitely not safe.

The major issue that happened to our newly purchased CX 90 last February 3 with more than 500 miles on it started around 5:30 pm of February 8, while my wife is driving this vehicle with my daughter, all of a sudden the car stopped at the middle of the road with warning signs popping up in the dash screen like I-active sense malfunction, hybrid battery malfunction, engine malfunction light on, and on top of these, critical vehicle malfunction. The car won't start and disabled. Also, the vehicle cannot switch to neutral gear to push/pull the vehicle to the side that made the vehicle blocking the roadway until the tow truck came in. My wife and daughter's life was put in danger when this vehicle suddenly stopped in the middle of the road with cars passing by on both ways. I also found out based on the NHTSA vehicle safety, Mazda recall website, carfax and Kelly blue book, that this particular vehicle with its VIN has a SAFETY RECALL due to its steering issue that may increase risk for crash. This was not disclosed to us when we are on the process purchasing this vehicle and they did state inspection and passed it that made we doubt how did it happened.. The vehicle is now with the dealership repair shop and the last update I receive was the technician is still checking on it.

Turning left at intersection at green light , the oncoming traffic sped up and I needed to floor it to not get hit. The my car switch to hybrid and went into a crawl pace. I had to floor it again to wake it up and get the heck out of the way. I don't think the computer is doing a good job talking to the hybrid system and the powertrain during emergency maneuvering. This can be dangerous. I know it scared the hell out me.

First took the vehicle for unscheduled service around 2,000 miles relating to engine noises, primarily rattling while driving. It's sporadic, but it sounds as if something was rattling underneath the car, primarily when accelerating, most noticeable when ramping up from slower speeds/lower gears. Also, when switching from drive into park, the engine makes unusual rumbling/rattling noises before settling into the regular engine idle rhythm. Finally, at 2,532 miles, the check-engine light came on, along with the message "Engine Malfunction. Have the Vehicle Inspected".

On 12/5/2023, upon turn after intersection, loss of power to the engine. Pushing gas provided no response from the engine. Engine power cut to about 10 miles an hour. Felt as the car was driving on battery - as no engine was heard. Was able to pull over to the side. Turned off and on engine 2-3 times but the power wasn't restored. Received warning on dashboard that there is malfunction with engine. Also received errors on Mazda application I had on phone. Engine light was on the dashboard. Photos attached. While obtaining assistance for tow service I was accidentally disconnected. I tried turning the car on again, and engine turned on normally. Total time between last unsuccessful turning on/off engine was about 10-15 minutes. First time experience such issue with loss of power and engine cutting off/ not working. Informed the car dealership and car repair/ check was scheduled to be brought to dealership for 12/8/2023. Estimated repairs taking 4 to 5 days before I can get the car back. Distance to dealership about 150 miles. Confidence in this car severely shaken - considering the price and the fact it is brand new.

These are two major problem i want to highlight, which need immediate attention One of them is related to steering wheel, which is a major safety concern for this vehicle to be on road. 1) Major safety concern- steering wheel Steering wheel is catchy when you are driving vehicle on high speed, which make this vehicle so difficult to control/ maneuver and struggling to keep this in a lane Steering wheel catchy means- it becomes hard when you steer and then skid before finally engaged. This makes driver nervous and can lead to an accident due to wavy drive 2) Engine malfunction light alert in instrumental cluster get on. This give you no choice whether to continue with vehicle. On Nov 23rd 2023, i was travelling with my family on [XXX] from ann arbor Michigan to columbus ohio and get stuck in highway due to this suddenly popped up Currently, vehicle is with germain mazda columbus and getting diagnosed. However, they confirmed some steering wheel motor problem and they are engaged with mazda corporate. But at the time of this reporting, they have this part backlog of 5 month and will be available by April 2024 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Vehicle low fuel indicators remained lighted up even after fulling up the vehicle tank. it appears is a faulty gas sensor, which if is not replaced can lead to false gasoline levels.