NHTSA complaint #11706157

Owner complaint summary

1. What component failed, and is it available for inspection? Component: The Engine Cylinder Head. The Failure: The cylinder head failed due to a structural crack caused by overtightened bolts (manufacturing defect), resulting in an engine oil leak. Confirmation: The defect is confirmed and resolved. Wayne Mazda (NJ) acknowledged the failure and replaced the cylinder head under the CPO Warranty last month. The issue has not returned since the replacement, proving this was indeed a hardware defect. 2. How was your safety put at risk? Fire Hazard: Before the repair, for a duration of one year, the vehicle leaked engine oil onto the hot exhaust manifold, creating a persistent fire risk. Toxic Exposure: My family and I were forced to inhale burning oil fumes inside the cabin for months due to the dealer's delayed diagnosis. This posed a significant health hazard. 3. Has the problem been reproduced or confirmed? Yes. The defect was initially identified by independent service centers (when the dealer failed to find it) and was ultimately verified and repaired by Wayne Mazda. The fact that the dealer performed the repair under warranty is an admission of the manufacturing defect. 4. Financial Damages & Request for Reimbursement: Since Mazda has admitted liability by fixing the vehicle, I request reimbursement for the losses incurred due to the delay in diagnosis: $2,000+ in Independent Repairs: Because Wayne Mazda initially failed to diagnose this warrantable defect, I was forced to pay independent shops to diagnose and attempt to fix the oil leak to keep the vehicle safe. These costs were a direct result of the dealer's inability to identify the manufacturing defect. $159.29 in Uber Fees: Mazda failed to provide a loaner vehicle during the major powertrain repair, forcing me to pay for my own transportation. Conclusion: I am filing this report to: Document this safety defect (Overtightened Cylinder Head Bolt / Oil Leak) for NHTSA records, as it poses a fire