My new 2006 Mazda 6 sedan that was purchased from the dealer 30 miles away from S.F.. right after driven home, it had the severe overheating smell inside and outside the car. Such overheating smell occurred even when moving the car to the curb. Dealer said it was new cars burning off smell. Took it to the local dealer: Changed the engine cooling thermostat, the radiator cap, coolant reservoir tank and re-flashed the powertrain. Was told that residual smell will linger for a couple weeks. The overheating smell persists inside the car when the air vent is set at cold outside air. Usually smell starts in about 5 minutes after a mile of ordinary city drive at 25 mph to 35 mph on flat road. It gets stronger and sometimes hot air blows in when the day is warm (around 68F to above 70F). If car is parked for hours in an open space after several miles drive, hot air and smell blows immediately at start and stay on. On freeway the smell is less strong but becomes very bad when exit to a stop sign. During the cooler days of 50F to 65F, the onset of the overheating smell is delay. There is no such smell in the vent air when set for ''warm'' air at night or at ''air condition'' to check if smell is from air duct. Now the car has 3000 miles on it and the smell problem still exists. A few times I have headache after driving with the smell. For this problem I have taken the car four times between both dealers and called the Mazda customer service center two times. Each time they did a pressure leak test and told me the car is ok within manufacturer''s specs. They all claimed that there is no such smell in the driving conditions as I described. Nothing is done because they cannot recreate the problem. Last month found oil stain under car and some radiator hoses turn white with powder. Last week the local dealer changed the leaking strut and the slightly leaking overflow tube to the coolant reservoir tank. It also said color change of radiator hose into engine is normal.

- San Francisco, CA, USA