2024 Mazda CX-90 fuel system problems

Filed Oct 19, 2026 · Electrical, Engine · AL

While driving through a busy intersection with my family inside the vehicle, my 2024 Mazda CX-90 suddenly experienced a complete loss of propulsion. Pressing the accelerator pedal produced no response, leaving the vehicle unable to accelerate or maintain speed. The vehicle displayed warning messages stating “Engine malfunction” and “Stop safely and shift to Park.” I was forced to rely on the vehicle’s remaining momentum to coast out of the busy intersection and into a nearby gas station. This unexpected loss of propulsion created an extremely dangerous situation and placed my family at serious risk of a collision with surrounding traffic. Following the incident, the vehicle was taken to Hiley Mazda, where technicians diagnosed a failed 48-volt mild-hybrid battery and ordered a replacement under warranty. A leaking radiator was also discovered during the same service visit. This vehicle has an extensive history of electrical malfunctions, abnormal i-Stop operation, software-related issues, and previous safety concerns. However, this incident was particularly alarming because the vehicle completely lost propulsion while operating in active traffic. I am extremely concerned that this type of failure could occur in other Mazda CX-90 vehicles, potentially resulting in a serious accident or injury. I am requesting that the federal safety agency investigate this sudden loss-of-propulsion failure and determine whether it represents a broader safety defect affecting Mazda’s 48-volt mild-hybrid system.

Filed Jun 29, 2026 · Fuel system, Suspension · TN

The lower fuel pump is going out. It is a known issue with the car. I was driving out of town and the car started to stall. My steering has become ruggish while on the trip as well, and steering was complicated during heavy winds. The car has been inspected by dealer and both warning lights have been cleared. But the issues still remain.

Filed Jun 2, 2026 · Electrical, Fuel system · TN

My 2024 Mazda CX-90 PHEV Premium Plus has experienced repeated hybrid system failures. The vehicle currently has an active "Hybrid System Malfunction" warning light. This is the latest in a series of 17 recalls and recurring defects since purchase in July 2023. Most recently, the vehicle was out of service from February 14, 2026 to approximately March 18, 2026 due to a severe transmission fluid leak, which the dealer (Nealson Mazda Cool Springs, TN) acknowledged was common in this model. The current hybrid system malfunction warning poses a direct safety concern as it affects the vehicle's powertrain and reliability. I am a daily driver of this vehicle and have two young children who ride in it regularly.

Filed May 12, 2026 · Engine, Fuel system · IL

My 2024 Mazda CX-90 MHEV has experienced multiple life-threatening sudden engine stalls and a complete loss of motive power while driving in active traffic lanes. The first incident occurred on December 31, 2024, when the vehicle abruptly shut down with an "Engine Malfunction" dashboard alert. The vehicle was towed to an authorized Mazda dealership (Palatine, IL), where it was held for a week, but technicians stated they could not replicate the issue and returned the car to me as safe. On March 30, 2026, the exact same failure recurred. While driving, the engine suddenly shut off completely at a traffic intersection. After turning the vehicle off for 5 minutes, it was restarted and driven to another authorized Mazda dealership (Crystal Lake, IL) for specialized diagnostic scanning. The second dealership successfully retrieved stored diagnostic trouble code (DTC) P061B, which is directly linked to safety recall 24V‑815 (Loss of Drive Power from Software Errors). Crucially, the detailed diagnostic scan revealed that this code was historically stored with a timestamp dating back to December 2024. This proves that the safety defect was active and detectable during the first dealer visit 16 months prior, but was completely missed by the first dealership, leaving my family with an ongoing crash hazard. To address the failure, the dealership replaced the low-pressure fuel pump in the fuel tank and a mass airflow (MAF) sensor. However, Mazda Corporate customer experience has formally stated to me in writing that they are "not in a position to guarantee the concern will not reoccur." Because this safety-critical propulsion failure causes the vehicle to suddenly die in traffic and has a documented history of ineffective recall remediation, it poses an unresolved, severe crash risk. The vehicle is currently in my possession and available for inspection.

Filed Apr 23, 2026 · Fuel system · NV

The fuel tank pressurization systems on my 2024 Mazda CX-90 PHEV have failed, and the vehicle is currently available for inspection at Dolan Mazda in Reno. This defect puts the safety of myself and others at risk because the vehicle gurgles and sprays raw gasoline out of the filler neck during refueling, creating a severe fire and environmental hazard at public gas stations. The issue first appeared on March 23, 2026, during a road trip from Reno to Las Vegas, with dashboard warnings stating Fuel Tank Malfunction, Avoid Refueling, Have the vehicle inspected and Engine Malfunction. The vehicle was inspected and supposedly repaired by Jerry Seiner Mazda on March 24, 2026, but the problem recurred during the return trip from Las Vegas to Reno on March 29, 2026, when it again spit fuel at the pump. The failures consistently occurred midway through long road trips at refueling stops in Tonopah, Beatty, and Hawthorne, Nevada. During these incidents, the vehicle was completely unable to accept fuel, causing significant distress as I was nearly stranded with young children in remote desert areas with limited resources. I barely managed to reach my destination on the remaining range. Although I have documented these specific malfunction messages and safety incidents, the vehicle has been at Dolan Mazda since April 17, 2026, where the dealer and manufacturer have been unable to reproduce the issue in a stationary shop environment despite it being the second formal repair attempt for a life-threatening fuel system failure.

Filed Apr 16, 2026 · Fuel system · NY

After multiple visits to the dealer—and despite a manufacturer recall addressing the issue of remaining fuel levels and estimated range—the error message has reappeared.During my most recent visit to the dealer, I was informed that they could not detect any errors.

Filed Apr 13, 2026 · Engine, Fuel system · TX

We believe the evaporative emissions control system (EVAP) / fuel vapor management system on our 2024 Mazda CX-90 MHEV (inline-6 mild hybrid) is malfunctioning, releasing strong raw gasoline vapors. The strong odor occurs everywhere around the vehicle while the engine is running and immediately after shutdown and exit. The problem is intermittent. No visible liquid fuel leaks have been observed. The vehicle and related components remain available for inspection upon request. This creates a direct safety risk: the hazardous flammable gasoline vapors are strong enough to migrate from our garage into our living space (house), posing a potential fire/explosion hazard if vapors accumulate near an ignition source, as well as a health concern from prolonged inhalation for our family. Raw gasoline vapors are highly flammable and should not be present in or around a residence. The problem has been reproduced and confirmed by the dealer on at least one occasion. On the third service visit (dropped off March 5, 2026), the strong raw gasoline odor was so intense upon arrival that multiple dealership personnel, including General Manager Weldon Munsey, witnessed it immediately, and one technician looked under the vehicle to check for liquid gasoline leaks. On the two prior visits, technicians were unable to replicate the issue. The local dealer has informed us that they are aware of two other CX-90s with the exact same problem occurring at the same time within their dealership network. Despite having no root cause, no fix identified, and no timeline for resolution, the dealer wants us to return the loaner and take our car home unrepaired. The vehicle was purchased new on [XXX], and currently has 39,213 miles. It has been inspected multiple times by the dealership (Roger Beasley Mazda Georgetown, repair order [XXX]). Mazda Corporate has an open investigation (their case [XXX]) and has assigned a case manager (Chris) who is currently reviewing the issue with the service INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATIO

Filed Apr 10, 2026 · Fuel system · PA

While my wife was driving my 2024 Mazda CX90 gas turbo at the posted speed limit, this vehicle suddenly without warning the car lost most of its power. She was able to move the vehicle to safety by pushing the gas pedal to the floor and achieved a maximum speed of 10 mph. The car was towed to the dealer Koch 33 of Easton, PA. The dealer diagnosed the problem as a throttle body issue. This is the second incident whereby this vehicle lost power in a similar manner but for a different reason (fuel pump) and had to be towed to the same dealer. I filed a complaint with your agency about 18 months ago. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Feb 26, 2026 · Engine, Fuel system · PA

The authorized dealer, Cochran Mazda, previously bypassed the vehicle’s hybrid system and returned the vehicle to us stating it was safe to operate and that we could disregard warning messages until a replacement hybrid battery became available. Prior to this, we had reported repeated drivability concerns, including jerking during operation. We were advised that this behavior was normal for hybrid vehicles. While awaiting a follow-up service appointment, the vehicle displayed a “Critical Engine Malfunction” warning and experienced a significant loss of power while traveling across the Liberty Bridge in Pittsburgh, PA. The vehicle would not accelerate beyond approximately 15 mph and then stalled out on the bridge. We activated hazard lights and were able to proceed slowly to a nearby parking lot, where the vehicle required towing. This incident created a hazardous traffic condition and raised significant safety concerns.

Filed Oct 26, 2025 · Engine, Fuel system · CA

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 the federal safety agency 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.