NHTSA Complaint #11712291 — 2023 MAZDA CX-30

My 2023 Mazda CX-30, which is currently under full manufacturer warranty, was brought to the dealer on October 10, 2025, specifically to address a safety defect involving white chemical particulates blowing through the HVAC vents. The dealership confirmed the failure of the "evaporative coating", which resulted in unidentified chemical byproduct being discharged directly into the passenger cabin.The vehicle remained out of service for 103 days due to this manufacturing defect. Upon receiving the Repair order (RO# 77004584) today, January 20, 2026, I discovered a significant safety concern that violates standard warranty repair protocols: the technician admitted to receiving two separate heater unit boxes that were damaged during shipping and subsequently 'transferred all salvageable items "from one damaged unit to the other to make one complete unit". As a consumer with a vehicle under warranty, I am entitled to a repair using new, undamaged factory parts. I am extremely concerned about the structural and functional integrity of a "reconstructed" HVAC system assembled from damaged components. Furthermore, despite the confirmed chemical emission, no professional decontamination of the interior was performed. The manufactures is now using financial threats of storage and rental car fees to force me to accept this substandard, "cannibalized" repair.