I have a 2009 mazda 6 2.2 diesel with 9200 miles on clock.I have just taken it to the dealer to replace the injection pump. This is the 2nd time in 13 months is there something I am not being told.

https://fusesdiagram.com/mazda/fuses-and-relay-mazda-6-2008-2012.html

You need to have the system reset by the dealer.

driving a car with no water in the engine generally causes major engine failure as from your description
the dealer will only fit new engine so find an accredited service center who has experience on your make of car
get quotes to fit service exchange engines from reputable engine reconditioner or good engines from wreckers or junk yards
You can get good rear ended write offs where the engine has not been affected and has low miles on the clock

BLACK SMOKE FROM DIESEL ENGINE COULD BE RESTRICTED AIR INTAKE CHANGE AIR FILTER.INJECTION PUMP TIMING TOO ADVANCE OR.FUEL NOZZLES DIRTY OR WORN, NOT SPRAYING ATOMONIZING FUEL CORECTLY.

Refer to Figures 1,2,3,4 when performing 17-step timing procedure for 1981-1985 Diesel Engines.

Fig 1. Injection pump and camshaft alignment marks - Diesel engine.




Fig 2. Removing the timing belt holder - Diesel engine.



Fig 3. Injection pump alignment marks - Diesel engine.



Fig 4. Tensioiner Pulley Bolt Sequence - Diesel engine.



Procedure - Timing Belt replacement.

1. Disconnect the negative battery cable. Drain the cooling system.

CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2. Remove the timing belt cover. Remove the injection pump sprocket flange.

3. Using a prybar, remove the tension spring from the timing belt tensioner.

When removing the tension spring, avoid using excessive force for the spring may become distorted.

4. Remove the tensioner pulley bolt and the pulley.

5. Remove the timing belt and discard it.

To install:

6. Rotate the crankshaft to bring the No. 1 piston to TDC of the compression stroke.

7. Align the timing marks on the injection pump sprocket with the camshaft sprocket; the marks must be facing each other.

8. Using a new timing belt, install it in the following sequence: crankshaft sprocket, camshaft sprocket and the injection pump sprocket; the slack must be between the injection pump and camshaft sprockets.

9. Install the tension center and the tension pulley so the end of the tension center is fitted against both pins on the timing pulley housing.

10. Hand tighten the nut so the tension pulley can be rotated freely.

11. Install the tension spring and semi-tighten the pulley nut to 22-36 ft. lbs. (30-48 Nm).

12. Rotate the crankshaft 2 full turns clockwise to seat the belt and further turn the crankshaft 90° beyond TDC to settle the injection pump.

13. Loosen the tension pulley nut to take up the timing belt slack. Tighten the tension pulley nut to 79-94 ft. lbs. (108-128 Nm).

14. Install the injection pump sprocket flange; the hole in the outer circumference of the flange should be aligned with the triangular timing mark on the injection pump sprocket.

15. Rotate the crankshaft 2 full turns clockwise to bring the No. 1 piston to TDC of the compression stroke. Make sure the triangular timing mark on the timing sprocket is aligned with the hole in the flange, then, measure the timing belt tension; it should be 33-55 lbs.

16. Install the timing belt cover.

17. Connect the negative battery cable.

Make sure all lines are light when turning engine over.While turning engine over loosen the a line closes to pump or the fuel filter.You should get some fuel.Then continue on all lines working farther away.

you can buy it in SURESTART DIESEL INJECTION SERVICES address Shaw Lne Industral Estate, Doncaster (01302) 340467

Have you run the car without fuel? There must not be any air in the fuel line... Blead the fuel line of air and try to start it. There should be bleader screws under the hood....

The problem is the SCV valve, that regulates the fuel pressure at the injection pump. The problem is solved when we replace that valve.

http://img263.imageshack.us/img263/2028/valvulacaudaldensojk2.jpg

In that link you have the picture of the valve and its part number.

isusu engine?? have you looked for a 8mm hole in timing gear that corresponds with a hole on plate behind then lock it in with a bolt ,remove bolt after tightening belt .DONT FORGET THIS ???.....if you cant find anything do it with no timing marks easy --- piston no 1 at tdc valves closed spin pump till fuel comes out of no 1 injector feed and lock it all together,indirect diesel is 6/8 ,,,,,direct injection is 12/16,,,,and turbo is 18/22 btdc