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[Solved] Mazda 6 2.0 Diesel 2002 - Engine Starting Issues After Head Planning, Injector Replacement

Piotr01m 14316 12
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  • #1 16942760
    Piotr01m
    Level 7  
    Posts: 6
    Rate: 4
    Hello
    I am asking for help, because I have problems with starting the engine in my Mazda.
    The problem arose when I decided to leave the heads for planning because it turned out that I was throwing a little coolant and I was covered with liquid from above. A mechanic I know advised that he gets left pressure. After planning, I was told it was actually very lopsided.
    The problem occurred when removing the injectors, one very hard went down after a few days of turning it and pouring it with kerosene, I was able to remove it.
    When assembling the car did not want to start, I gave the injectors to be checked and it turned out that one was completely damaged. So I bought a stimulant, installed it, vented the entire fuel system, connected the injection plugs and the car started. I left it running with 30 minutes, so I got on a ride with 1km and the car went out at the intersection and it does not start at all. The starter is spinning, but it won't stick at all
    I am asking for advice on the subject
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  • #2 16942812
    Browc70
    Level 12  
    Posts: 54
    Help: 3
    Rate: 22
    I think that errors would help a lot in diagnosis, so you can visually see if all the plugs are in place, maybe one of them has broken, the computer will explain the rest.
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  • #3 16979034
    Piotr01m
    Level 7  
    Posts: 6
    Rate: 4
    After checking the computer, the mechanic had an error P0380 and it was related to the lack of connection on the Zarowe candle strip, the candles did not work at all, so they were replaced with new ones, but the error still pops up. In addition, there is still low pressure on the injection rail despite the replacement of the SCV valve, the mechanic claims that the pump went. Today it will be sent to be checked so we will see if there is a problem
  • #4 17308823
    dabrowski marek
    Level 11  
    Posts: 91
    Help: 3
    Rate: 66
    Dude, I will be gloomy about this scheme or maybe you got it because I have a damaged driver and exactly it does not give voltage on the scv
  • #5 17309598
    Piotr01m
    Level 7  
    Posts: 6
    Rate: 4
    Unfortunately, I do not have this diagram, I am struggling with the problem, after replacing the pump and the SCV valve with a new car, it fired and I was happy only for a week because the traction control pops up and the car goes out ...
  • #6 17309924
    thomas-cs
    Level 14  
    Posts: 277
    Help: 15
    Rate: 35
    Check the masses at the left lamp carefully. Such a white cube screwed to the kennel. A very common problem with these mazdas (I myself had :) ). The sheet metal to which the mass is screwed rots, but also the cube itself tarnishes and there are often problems with firing or lights. It's best to cut the cube and earn new connections. In addition, the beam that goes that way next to the intercooler likes to rub and strange errors pop up.
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  • #7 17310125
    Piotr01m
    Level 7  
    Posts: 6
    Rate: 4
    Hmmm thanks for the advice, I'll check it out too
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  • #8 17310826
    dabrowski marek
    Level 11  
    Posts: 91
    Help: 3
    Rate: 66
    Regarding the traction control, it also lights up when the coolant temperature sensor is damaged, the one on the head or the fuel temperature sensor on the pump, check the elm327 readings plus the forscan program, when there is any damaged car, it will also go out when you are from the Wałbrzych area, we can somehow contact us, we'll get it topic
  • #9 17310885
    Piotr01m
    Level 7  
    Posts: 6
    Rate: 4
    Hello
    Today I gave the car to an electrician, after the initial analysis of the reading from the computer, there were errors regarding a leaky fuel system and an error with CAN regarding the lack of communication. Unfortunately, I do not know the error codes, but I will wait for a thorough analysis of the electrician.
    Everything is strange that the car will start normally, but when its revs drop below 1000, the car goes out at the same time, the traction light turns on and it does not light up until the computer is reset by removing the clamps from Aku or after turning the ignition key several times to the ignition level. When the traction control goes out, the car will fire again, I will add that the engine error was not displayed once.

    I will mention these tips to the electrician, maybe he will find the trail sooner.

    Added after 2 [minutes]:

    I am from the vicinity of Silesia, from the town between Cz-wa and Kato. I have a piece to Wałbrzych, but thanks for the advice :)
  • #10 17310945
    dabrowski marek
    Level 11  
    Posts: 91
    Help: 3
    Rate: 66
    Let the electrician give you the exact error codes, I know this system quite well and I think I have already worked through all possible faults I am in the process of repairing the driver because it does not control the scv.
  • #11 17311191
    Jackall
    Level 27  
    Posts: 851
    Help: 77
    Rate: 393
    In a maze, the traction control lights up when any engine sensor is damaged, or there is something wrong. I had a case of this indicator, and there was a shaft sensor error (sheared wedge on the pump vacum side) after repair, test drive and the crankshaft broke. The customer was happy ... But he took the chest and broke 7000 for the repair of the motor and the replacement of the dual mass.
  • #12 17311329
    dabrowski marek
    Level 11  
    Posts: 91
    Help: 3
    Rate: 66
    Before you buy a Mazda, find a reliable mechanic ?
  • #13 17338283
    Piotr01m
    Level 7  
    Posts: 6
    Rate: 4
    Hello
    The problem has been solved, I hope for good. The electrician did not find any problems with the car and he was right, after picking up the car I did the overflow test again and it turned out that one injection (another time) was pouring. At this point, I understood the cause of such frequent injection damage, because it is already the 4th time. In my opinion, the problem was with a contaminated fuel system, I checked the fuel filter, which had not been changed for a year and it looked tragic. Apparently the filter sucked the fuel tank and damaged the injectors.
    I replaced the injection with another used one + fuel filter + additional fuel filter on hoses, the repair took me 20 minutes. I have been the owner of this car for over 6 years, so this is not a fresh purchase and problems started to appear, as I mentioned after replacing the head gasket.
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Topic summary

✨ The discussion revolves around starting issues with a 2002 Mazda 6 2.0 Diesel after head planning and injector replacement. The user experienced coolant leakage and had the heads planned, but faced difficulties with injector removal and subsequent engine starting. After replacing a damaged injector and venting the fuel system, the car initially started but stalled shortly after. Error codes indicated issues with the glow plug circuit and low pressure in the injection rail, leading to suspicions about the fuel pump. Further diagnostics revealed a leaky fuel system and communication errors. Ultimately, the user identified a contaminated fuel system as the root cause, replacing the fuel filter and injectors, which resolved the starting issues.
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FAQ

TL;DR: Case study: 4 injector failures traced to a clogged fuel filter; "one injection was pouring" after an overflow test. Root cause was dirty fuel, fixed by injector replacement plus new and added filters. [Elektroda, Piotr01m, post #17338283]

Why it matters: If your Mazda 6 2.0D starts, idles, then dies or flags traction control, a dirty fuel system and injector overreturn may be the culprits—this FAQ shows what to check and how to fix it.

Quick-Facts

Quick Facts

What most likely caused the starting and stalling after head work and injector removal?

Contaminated fuel clogged the filter and damaged injectors, causing overreturn and stalling. The owner saw repeated injector failure until replacing the bad injector, renewing the fuel filter, and adding an inline prefilter. Symptoms cleared after cleaning the fuel path. [Elektroda, Piotr01m, post #17338283]

What does code P0380 indicate in this case?

P0380 appeared with a noted lack of connection on the glow-plug rail. The glow plugs were inoperative and replaced, yet the P0380 code still returned. That points to a circuit or wiring issue on the glow-plug strip rather than the plugs themselves. [Elektroda, Piotr01m, post #16979034]

Why did low rail pressure persist after changing the SCV valve?

Low rail pressure continued despite a new SCV. The pump was suspected and replaced, the car ran for a week, then traction-control faults and stalling returned. That pattern supports a fuel-system contamination root cause rather than only a control-valve problem. [Elektroda, Piotr01m, post #17309598]

How can a clogged fuel filter damage injectors on the Mazda 6 2.0D?

A neglected filter can pass debris to injectors, increasing leakage (overreturn) and rail-pressure loss. In this case, the filter “looked tragic” and was linked to four injector failures. Replacing the filter and adding a prefilter stopped further damage. [Elektroda, Piotr01m, post #17338283]

How do I perform a quick injector overflow (return) test?

  1. Warm the engine if possible and attach clear tubes to injector return ports.
  2. Crank or idle briefly, watching for excessive return from any injector.
  3. Replace any injector with clearly higher return than the others. This test identified the failing injector here. [Elektroda, Piotr01m, post #17338283]

Why did the traction-control light come on with engine issues?

On this Mazda, traction-control can illuminate for engine-sensor faults. As one expert noted, “traction control lights up when any engine sensor is damaged.” Treat it as an engine diagnostic clue, not just a chassis warning. [Elektroda, Jackall, post #17311191]

Could poor grounds near the left headlamp cause no-start or stalling?

Yes. A corroded ground “white cube” by the left lamp is common. The advice: “Check the masses at the left lamp carefully.” Also inspect the nearby harness by the intercooler for rubbing and intermittent faults. [Elektroda, thomas-cs, post #17309924]

The engine starts but dies below 1000 rpm—what does that suggest?

The reported behavior was normal start, then stall as rpm dropped under 1000, with traction light and CAN communication error logged. That combination points to fuel starvation or unstable sensor signals. Fixing the fuel system resolved it in this case. [Elektroda, Piotr01m, post #17310885]

What is the SCV valve here?

SCV refers to the suction control valve on the high-pressure pump. It meters fuel into the pump. If the ECU or wiring fails to drive it, rail pressure can drop and the engine may stall. One user traced faults to SCV control. [Elektroda, dabrowski marek, post #17310945]

Which DIY tools can I use to read live data on this platform?

Users referenced an ELM327 interface with FORScan to check sensors like coolant or fuel temperature and to read fault codes that explain stalling and traction warnings. It’s a practical, low-cost combo for Mazda diagnostics. [Elektroda, dabrowski marek, post #17310826]

Can traction-control faults connect to serious mechanical failures?

Yes, one case showed a sensor-related fault, then a sheared wedge at the vacuum-pump side, followed by a broken crankshaft after test drive. It’s an edge-case, but illustrates investigating sensor errors promptly. [Elektroda, Jackall, post #17311191]

What finally fixed the OP’s Mazda 6 in this thread?

A failing injector was confirmed by an overflow test. Replacing that injector, installing a new main fuel filter, and adding an inline hose filter solved the problem. The car then ran normally after these steps. [Elektroda, Piotr01m, post #17338283]

How should I prevent repeat injector failures after head-gasket work?

Renew the fuel filter, flush contaminated fuel, and consider a temporary inline prefilter. Confirm injector health with an overflow test before extended driving. This approach ended a cycle of four injector failures in the documented case. [Elektroda, Piotr01m, post #17338283]

What were the very first symptoms after reassembly?

After venting the system and reconnecting injector plugs, the car started and idled for about 30 minutes. A short 1 km drive followed, then the engine died at a junction and would not restart. That sequence suggests marginal fueling. [Elektroda, Piotr01m, post #16942760]
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