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Home >> Mazda >> 2002 >> MX-5 Miata Base, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0442: EVAP Control System Small Leak Detected >> Diagnostic Procedure

Diagnostic Procedure

  1. Turn ignition off. Connect New Generation Star (NGS) tester or equivalent to OBD-II Data Link Connector-2 (DLC-2). See Figure. Turn ignition on. Monitor for FREEZE FRAME DATA and ensure data has been recorded. Check for service bulletins and/or other line of repair information related to this DTC. If repair information is available, perform diagnosis and repair as necessary. After repair, go to step  18. If repair information is not available, go to next step.
  2. Leave ignition on. Monitor for other DTCs. If malfunction code recordedis P0442, go to next step. If malfunction code recordedare P0443 and/or P1449, follow appropriate DTC diagnostic procedure.
  3. Turn ignition off. Inspect fuel filler cap for installation (loose) or damage. If fuel filler cap is properly install and no damage is found, go to next step. If fuel filler cap is faulty, either reinstall properly or replace fuel filler cap. After repair, go to step  18.
  4. Inspect whole system of EVAP system, see WHOLE SYSTEM INSPECTION under SYSTEM LEAK INSPECTION - USING VACUUM PUMP under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If NGS tester or equivalent value holds for a minimum of 2 minutes, no leaks were detected in EVAP control system. Go to step  14. If NGS tester or equivalent does not hold value for a minimum of 2 minutes, if evaporative emission tester is available, go to step  13. If tester is not available, go to next step.
  5. Inspect leak from charcoal canister to fuel tank, see INSPECTION FROM CHARCOAL CANISTER TO FUEL TANK under SYSTEM LEAK INSPECTION - USING VACUUM PUMP under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If NGS tester or equivalent value holds for a minimum of 2 minutes, no leaks were detected in EVAP control system. Go to step  8. If NGS tester or equivalent does not hold value for a minimum of 2 minutes, go to next step.
  6. Remove fuel tank and visually inspect fuel tank and attached accessories for damage, insufficient sealing, or poorly attached accessories. If fuel tank and accessories condition or sealing are okay, go to next step. If fuel tank accessories condition or sealing are faulty, repair or replace fuel tank, fuel tank accessories or sealing components as necessary. After repair, go to step  14.
  7. With fuel tank removed, inspect rollover valves, see FUEL SHUT-OFF/ROLLOVER VALVES (MIATA) under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If rollover valve is okay, inspect hoses from charcoal canister to fuel tank for detached, incorrectly installed or cracked, repair or replace if necessary and go to step  14. If rollover valve is faulty, replace rollover valve (Rollover valve is an integral part of fuel tank. If rollover valve is faulty, replace fuel tank). After repair, go to step  14.
  8. Inspect leak from charcoal canister to PCSV, see CHARCOAL CANISTER TO PURGE SOLENOID VALVE under SYSTEM LEAK INSPECTION - USING VACUUM PUMP under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If vacuum holds for a minimum of 2 minutes, no leaks were detected in EVAP control system. Go to step  14. If vacuum does not hold for a minimum of 2 minutes, go to next step.
  9. Remove catch tank. Plug one port, using vacuum pump apply vacuum at other port. Inspect for plugging, damage or pinhole leaks. If catch tank is okay, go to next step. If catch tank is faulty, replace catch tank. After repair, go to step  14.
  10. Remove PCSV and perform inspection. For inspection, see PURGE SOLENOID VALVE - AIRFLOW INSPECTION under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If PCSV is okay, go to next step. If PCSV is faulty, replace PCSV. After repair, go to step  14.
  11. Remove Charcoal Canister. Inspect for plugging, damage or pinhole leaks. For Charcoal Canister inspection, see CHARCOAL CANISTER under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If Charcoal Canister is okay, go to next step. If Charcoal Canister is faulty, replace Charcoal Canisterand go to step  14.
  12. Remove CDCV and perform inspection. For inspection, see CANISTER DRAIN CUT VALVE (CDCV) - AIRFLOW INSPECTION under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If CDCV is okay, inspect hoses from charcoal canister to CDCV for detached, incorrectly installed or cracked, repair or replace if necessary and go to step  14. If CDCV is faulty, replace CDCV. After repair, go to step  14.
  13. Inspect EVAP control system for leaks using evaporative emission tester. See FUEL-FILLER CAP INSPECTION under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If component is okay, go to next step. If component is faulty, replace component and go to next step.
  14. Return vehicle to original condition. Implement Evaporative Emission System Tester Self Test and Leak Inspection, even if vehicle is not on test condition. See EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article.If EVAP system small leak test is faulty, go to next step. If EVAP system small leak test is okay, go to step  18.
  15. Using NGS tester or equivalent, clear DTCs from PCM memory. Check if repair shop conditions are appropriate to perform Drive Mode 4. If shop conditions are okay, go to step  17. If shop conditions are not okay, go to next step.
  16. With no DTCs store at PCM memory, implement Evaporative Emission System Tester Self Test and Leak Inspection again. See EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article.If system is faulty, replace PCM. After repair go to step  18. If system is okay, go to step  18.
  17. Run EVAP Monitor Repair Verification Drive Mode 4. See MODE 4 - EVAP SYSTEM REPAIR VERIFICATION DRIVE MODE  under DRIVE MODES. Stop vehicle and using NGS tester or equivalent access ON BOARD SYSTEM READINESS TEST to inspect Drive Mode completion status. If EVAPORATIVE PURGE SYSTEM has been monitored, go to next step. If EVAPORATIVE PURGE SYSTEM has not been monitored, go back to step  15.
  18. Return vehicle to original condition. Using NGS tester or equivalent, clear DTCs from PCM memory. Access DIAGNOSTIC MONITORING TEST RESULTS of generic OBD-II functions and verify TEST ID 10:21:00 value. If value is above MAX value, replace PCM. For PCM removal and installation, see POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION article. Monitor for other DTCs. If any other DTC is present, follow appropriate DTC diagnostic procedure.
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