NHTSA complaint #11583290

Owner complaint summary

Cylinder head cracked resulting in engine overheating with code P111A. Gasket bolts expelled due to excessive heat and pressure. Evidence of coolant spray along hose connections, lower cover and transfer case. Smoke came out of the engine compartment first followed by warnings titled 'Critical vehicle malfunction alert' 'pull over immediately' Check engine light came up shortly thereafter. Vehicle inspected by an authorized Mazda service center, confirming the engine overheat code. This is the statement from the service representative: 'Mazda wants to start with a cylinder head prior to doing an engine'. The technician's analysis indicates they received warranty approval for Entire cylinder head and head gasket replacement and all associated parts. No warning lights prior to the failure. They started just as the engine started smoking. Potentially related information: The vehicle displayed error code for a coolant valve issue 3 weeks before this issue for which a TSB already existed and Mazda replaced the part. TSB related to cylinder head defect exists for model year 2019, but not for model year 2022.