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Mazda3 2.2D Knocking after changing injector seals


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jaboi
New User

Mar 31, 2023, 12:52 AM

Post #1 of 3 (1651 views)
Mazda3 2.2D Knocking after changing injector seals Sign In

Hi folks,

My 3 sport 2.2D 2011 had the classic leaking diesel into the oil (common with MZR-CD R2AA engine). Got the garage to drop the sump and clean the inlet filter which was full of crud. Was running fine and stupidly thought I’d save myself the cost of cleaning the oil pick-up filter every year and just replace the injector seals.

Injectors 3 and 4 came out easy, were covered in diesel but okay. Injector 2 came out with some force and patience. Quite a bit of build up on this one, the seal was left stuck at the bottom of the hole. Injector 1 took hours to get out, using a 30mm spanner and extension bar on the body of it to twist free, this was the worst one. Again the copper seal was left at the bottom of the hole. I tried my best to clean out the holes but there was quite a lot of carbon and I didn’t have a tool to remove the washer. It’s possible a few crumbs of the soot fell into cylinder at this point.

I replaced the seals on 3 and 4, cleaned up and put back all the injectors. I overtightened them at first, probably to double their spec without thinking. Looked up and found that apparently it’s 9Nm. Did them to that, and then read elsewhere they’re 4nm so tried that too. It was knocking and running like ****** now whilst it was fine before all this. Changing the torque slightly on those dodgy injectors seemed to get rid of the knock or make it worse, it was super sensitive.

I got it towed to a local garage because the knocking is that bad. Told them and they have reseated all the injectors with new washers, found 2 injectors were uncoded and coded them in. But the knocking is still there as in video. They’ve said they’ve done all they can and there is some underlying issue.

VIDEO OF ENGINE RUNNING
https://youtu.be/80boMraZ2gQ

But it was honestly fine before I bothered to try this ******. I’m thinking either:
- The garage didn’t get a good seal on the injectors either
- whilst removing the stuck injectors I managed to damage one or both and they aren’t spraying properly

I haven’t any fault codes… any ideas? I'm thinking I just get a couple used injectors and see if that works.


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Mar 31, 2023, 4:36 AM

Post #2 of 3 (1634 views)
Re: Mazda3 2.2D Knocking after changing injector seals Sign In

IDK if this is even sold to the US in any version AND not a diesel tech so 2 strikes.
What I see is you've both over torqued things and the spanner tool may have damaged something?

Crud in a filter if not water TMK (diesels) hate water, air in lines.

Wait for another to come by but think shop should have finished what wasn't done or maybe if told seen damage. A maybe - this could be a disaster? Hope not,

Tom



Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Mar 31, 2023, 7:00 AM

Post #3 of 3 (1620 views)
Re: Mazda3 2.2D Knocking after changing injector seals Sign In

I'm afraid nobody here has any experience with this vehicle, engine or problem.



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