Author Topic: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS  (Read 23511 times)

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Offline matthewjtalbot

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #15 on: December 15, 2013, 09:57:49 PM »
Hi guys.

I know it a few months since i posted this post, so i thought i would update yuo with the most recent activities.

After the previous problems i hoped things were sorted.  But 10 days ago m y wife came home with a messgae that the oil light flickered again momenterily on her way home from work.  She drove it back home very carefully and we parked it up for the night.

Following day i decided that the same thing had happened again so towed the vehicle to my brother garage and set about checking things through again.  Pulled the sump off and yep :( :( :( the strainer pickup for the oil pump was absolutely solid in carbon again.

At that point i decided that it must almost certainly be a leaking injector seal.  so bit the bullet and went to mazda to price the parts.  I was expecting £40 for a set of 4 (£10 Each) maybe but to my supprise they were only £22 for a set of 4 seals.  Ok they are just glorified copper o-rings.  but they are manufacturer parts, so was fairly happy with the price and the fact they stocked them so i got them.  While there i also got them to check with a mechanic what the torque setting were for the injector clamps and the fieeds pipe unoins.

I didnt know what was involved it replacing them but on some invstigation work and removing the rocker cover plastic sheild  it looked very easy.

So really this is a post to advise that in my opinion and mazdas opinion that the cause of the carbon is caused by leaking injector seals allowing carbon deposit past the injectors and into the rocker cover.  Thus being washed into the sump and picked up by the pump. 

So i set to doing the repair.  This us a list of whats needed to be done.

1,  Jack car up and put on axle stands
2,  Remove plastic engine dirt sheild.
3,  Drain oil and remove sump.
4,  Using a slide hammer and L shaped adapter for end, insert the L shaped adapter through hole
     in the oil pick plate and going around the very inside edge of the plate,  hammer the plate out.
     BE VERY CAREFUL as the trapped oil above oil pickup filter is about 100ml so soaks you through
     nicely if yyour not careful
5,  Clean the strainer, plate and de-silicone sump plate ready for re-fitting but do not refit
     ANYTHING YET.
6,  Remove engine plastic cover
7   Now you can see whats required.  Disconnect battery, but make sure you have radio code 1st. 
8,  Once battery disconnected leave for a few mins to allow the fuel pressure to drop in the
     injection system.  Unplug all 4 plugs to the top of the injectors.  Undo 2 x 10mm bolts holding
     injector plug harness, and pull fwd for clearance.
9,  Put a good piece of utra clean cloth or blue paper roll under both ends of all 4 injector pipes.
     Undo all injector pipes making sure you undo each one with a cloth over the union to stop any
     fuel spraying out (none sprayed on mine so you should be o.k ) Once undone use a marker pen
     and label pipes 1 2 3 4 and put them all in a plastic sandwich bag or put somewhere very
     clean.  Release and move aside the rubber return pipes that are on the top of each injector too.
10, Next undue the 8 little 10mm nuts holding the injector retaining clamps in place.  These 8 bolts
      are the cause of all the issues i have been having.  When i spoke to mazda they informed me
      the torque wrench setting is 4Nm but my injector 4 was at about 2Nm and hey presto this was
      the injector that was solid in its hole.
11. Remove the injector clamps and remove as many injectors by twisting them with your hand. 
      They should come out easy if they haven't been leaking. The ones that have been leaking will
      vary from being a little stifffer to remove than the rest, to, bvbeing solid in its hole.  My no.4
      was solid to point i could'nt even turn it.  So what i did was remove the posts the injector
      clamp bolts over. Then using an adjuctable spanner on the body of the injector not the solenoid
      top, i twisted the injector until is was loose enough the pull free with a little prying under the
      injector. Be careful not the pry against the rocker cover, its plastic.
12, Once the injectors are free, clean them up very carefully.  clean the injector wells and remove
      any old seals from the wells too.  i used a wet and dry vac to clean out the wells and a long
      thin piece of clean rag too on a long screwdriver.  The well the stuck injecter came from i used a
      screwdriver and the vacume to clean the seal seats as good as new again.
13  The re-fitting is the reversal of the above. the new seals for the injectors have a minute step at
      the very outer perimeter of the seals on 1 side, this faces upwards.
14, When bolting the injectors in place remember to torque them to the correct torque setting and
       i also put a tiny blob of thread nut lock onto the nuts once they were torqued correctly too.

Torque setting. 
Mazda 4Nm for injector clamps but AutoData says 9Nm.   I did mine to 10Nm just incase
Sump bolts are 10Nm

So i will keep you posted on the outcome of all this when i have a few more miles on the car after the repair but i have done 500 already and the average fuel economy has gone back to 52 to 55 like it was when new and there is deffinitely a slight increase in power and it idles better and is totally smoother like it was when new.

Sorry this post is a bit long but i hope it helps you think about tackling this instaed of being scared or putting it off coz you not sure, beleive me its quite straight forward if you have only basic mechanical experience.

Cheers Guys and Gals

Matt

Offline Neil P

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #16 on: December 15, 2013, 10:50:12 PM »
Great walk through Matt.

I have just bought a brand new 185 sport Nav which went into the garage to have a timing chain replaced under warranty with under 500 miles on the clock, doesn't install much confidence really does it.

The 150 Sport I had before had the oil light come on but that was due to the fact that I had gone 12 miles over the service interval and so I have been told the oil light doubles as a service indicator?

Have just traded the old car in against the new one but like you I think I'll be getting the strainer checked every six months. I have a service plan with the new car so if the sump comes off when they do an oil change the extra cost should hopefully be included if I ask nicely  ;)
1980 1.6 Mk2 Escort Sport
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1987 2.8V6 Sierra XR4x4 Hatchback +
1980 1380 Mini Clubman GT
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Offline Bubbs

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #17 on: December 28, 2013, 05:01:11 AM »
Something I didn't mention in my post, was that the hissing #3 injector was found to be hissing because it was loose - I guess due to never having been tightened properly since day one (similar to Matt's #4 one).

The garage actually tightened the bolts up when it was looked at earlier in the year, but in the end I never got as far as getting the seals replaced. I took the decision instead to plonk some dosh down on a new car (one with a 5 year warranty, just in case - and no, not a Kia or a Vauxhall!).

Whether the tightening of that #3 injector would have been sufficient long term or not, I don't know. Although mine had done almost 20K less than Matt's had/has when the issue first appeared, so perhaps it would have been sufficient.

If this had been an issue which was easy to monitor (without taking the sump off all the time), then I think I'd have hung onto the car, it's a bit of a shame that such a relatively small issue can have huge, expensive, consequences - and all because the injectors are positioned in such a way as to allow carbon blow-back deposits to enter the engine oil.

Offline Steve22150

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #18 on: July 12, 2014, 05:00:29 PM »
I understand this is an old thread but would like to provide further warning to current and potential mazda 2.2 diesel owners.
I too, have just become the latest 'victim' of the leaking injector seal problem that plagues these cars.
My 2009 Mazda 3 (150) is just approaching 50k and has been fully serviced by Mazda, on time, from new.
Last week the oil pressure light started flickering and I feared the worst. The excellent original warning posted on here by Matthew, and subsequent contributions, certainly helped to pinpoint the cause, thanks very much for that guys.
What really sickened me was the fact I've just agreed to trade in the car (for petrol toyota) and was just awaiting finance arrangements to go through before changing over.
Obviously, I couldn't continue driving the car (or trading it in) in that state and risked serious damage to the engine. I had nightmare vision of having to use the finance to pay for a new engine rather than a new car.
No option then but to take it to Mazda dealer in last week of ownership. Sure enough, the inline strainer was choked with carbon from leaking injector seals. Four and a half hours later(!) and at a cost of £300 (!) the problem was rectified.
This is clearly a known problem with these engines ( I understand there's even been a technical bulletin issued) yet no recall?? No surprise there though.....
It reaffirmed two things to me, I'm doing the right thing getting rid of the car and I won't be buying a Mazda again.
This is an engine which is proving to be costly and unreliable as the miles build up and I recommend owners of these to consider getting rid sooner rather than later. Furthermore, the dreadful (and greedy) after sales service from Mazda dealers is enough to dissuade anyone from entering their showrooms again.
One disappointed (soon to be ex) mazda owner.

Offline bman2012

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #19 on: August 07, 2014, 02:48:44 PM »
Afternoon everyone,
just wanted to add to the list of the people with this issue, sure enough my lovely 2.2d 150 has done the same to me this lunchtime. it went to the dealer for oil light flickering they decided it needed a service and other bits, so paid £525 for it to be done, got a day down the road and the light is on and staying on, the car makes noises like i have never heard!!! :(

Go straight back to dealer at lunch and tech takes one look and proclaims 'its the timing chain mate, really common this' its now there waiting to be looked at properly, with a  ballpark of 'At least £1000'

I'll get them to check the injectors while it is there.

Car is on 62000 miles, with a full service history from the Mazda dealer. I'm hoping to speak to Mazda and get some sort of goodwill

Has anyone had any good experience with Mazda themselves ?? :-\
Is the timing chain a check on the schedule ?

thanks

Offline rhomer

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #20 on: February 21, 2015, 02:12:19 PM »
Glad I saw these posts. My 59 plate Mazda 3 150 sport (57k miles) has just suffered from this exact same issue. Since it was winter I didn't want to be sorting this out on the drive so I to to a very good local garage. All 4 injector seals were leaking but 1 injector took them nearly 4 hours to remove! Glad I wasn't doing this outside!!

If anyone is interested in which garage did the work Bradford / Leeds area then PM me.

Offline speedy mazda

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #21 on: February 22, 2015, 07:34:38 PM »
hi bman perhaps get them to check the oil strainer in the sump incase its blocked as the chain usually gets slowly noisy  i would say as it gets loose slack.

Offline cwilliams255

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #22 on: August 09, 2019, 09:05:54 PM »
Old thread but after 10 years and 150k miles of ownership the dreaded oil light flickering has started has started on my 2009 2.2D.

Its really strange how it started, went for aircon regas due to failure on hottest day of year a couple of weeks back but it was full (even after 10 years :D), so suspect compressor failure , left the garage started to drive to work and oil light flickering. Pulled over, checked level, check for any odd noises nothing out of ordinary. Engine on and then off and light gone, drove about 50 metres and it was back. Pulled over again, rang garage I have it serviced at, they said to bring it in. I started to drive there but light immediately out and stayed like that so when i was 50% of the way to garage I decided to go to work instead. On drive home, all fine, except a small flicker for a few seconds and some slightly odd noises.

Its been well looked after with oil changes every 6k and is taken care of by a mazda specialist so I'm a little surprised, it was only serviced about 300 miles ago, maybe they don't check the strainer. While looking around this evening I noticed the aircon compressor was covered in oil but unsure if this is unrelated as its right next to the filter anyway.

What really annoying is it just had a brand new genuine mazda exhaust (£500 part) as part of service / MOT

I've loved owning this car so I don't really want to part way just yet. I'll get to the strainer tomorrow and see what's going on but hoping I can get a few more miles out of it. Happy maybe isn't the right word as this thread is at the expense of others misery but glad someone's taken the time to write up about it all the same.

Offline cwilliams255

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #23 on: August 14, 2019, 09:45:57 PM »
So I think I got lucky. Number 3 injector was leaking, lots of carbon build up in cylinder head and lots more in oil strainer hence oil pressure light. One very tiny metal piece in oil, now I know there should be no metal in my oil but at 150k miles I'm not going to fret too much about it. Cleaned everything up, fitted new injector washers, new oil, new filter, started up ok and running fine. Sounds fine, fine at full power, fine at high revs. Will be checking strainer again in about 1k miles and changing oil again to make sure all clear.

Will add some pics in next couple of days

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Re: Oil Light Flicker / Stays On. CALLING MAZDA 3 & 6 2.2D DRIVERS
« Reply #23 on: August 14, 2019, 09:45:57 PM »