NHTSA Complaint #11635169 — 2019 MAZDA CX-5

Car was purchased in June 2019. Car started smelling like burning oil and started finding oil pooling under the car around November 2024. At time the incident was discovered, car only had 38k miles. There was no warning lights or indication there was an issue other than the smell and small pool of oil under car. The Mazda service manager immediately knew what the issue was and told me they were going to confirm with a full inspection and diagnosis. I was told that I have a cracked cylinder head and I will need to have it replaced. Warranty ended few months prior so they will not cover. I was told it would cost $4589.76. The Mazda service department told me that this is a common issue and to hold off on repair and contact Mazda corporate since warranty just ended. They topped off my oil and told me to keep an eye on the oil level and to wait to hear back from Mazda corporate.I submitted a case with Mazda and the customer care specialist told me that they cannot guarantee they will cover this. Within a week, the temperatures got colder and issue got worse. Low oil light came on, topped off with oil. Lost 4 quarts in one day. Called Mazda service and they told me to top off oil and come drop car off immediately. Upon researching this issue, the cracking of cylinder heads in Mazda CX-5 vehicles, particularly those with the 2.5-liter (NA) engine were widespread and discussed in online forum. The contributing factors of the issue point to a design flaw of the cylinder head due to the cylinder deactivation technology and a manufacturing defect due to the cylinder head casting process based on reports and discussions within the automotive community. A TSB (SA-013/22) has been released for the affected cylinder head with a modified replacement. This seems to be a significant and widespread issue that can cause entire engine to fail and require full replacement. Oil leaking on to the hot exhaust near other engine parts could ignite and put myself or others at risk.