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Home >> Mazda >> 2002 >> Protege ES, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0456: EVAP Control System Leak Detected, Very Small Leak >> Diagnosis & Repair Procedure

Diagnosis & Repair Procedure

  1. Turn ignition off. Connect scan tool to DLC-2. Turn ignition on, engine off. Monitor for FREEZE FRAME DATA and ensure data has been recorded. Check service bulletins for repair information related to this DTC. If repair information is not available, go to next step. If repair information is available, perform diagnosis and repair as necessary. After repair, go to step  13.
  2. Turn ignition switch off and then start engine. Check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If DTC P0456 is present, go to next step. If any other DTCs are present, go to appropriate test.
  3. Perform evaporative emission control system leak inspection. 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 passed, problem is intermittent. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES article. If system failed, go to next step.
  4. Using ultrasonic leak detector (part of evaporative emission system leak tester). Locate leak at following:
    • Catch tank
    • Charcoal canister
    • Fuel filler cap.
    • EVAP hoses and pipes.
    • Fuel tank.

    Repair leak or replace part as necessary. After repair, go to step  9. If no leak was found go to next step.

  5. Disconnect purge solenoid valve tube coming from intake manifold. Connect vacuum pump to purge solenoid valve. Apply vacuum and wait 5 seconds. If valve holds vacuum, go to next step. If valve does not hold vacuum, replace purge solenoid valve. After repair, go to step  9.
  6. Reconnect all disconnected hoses and connectors. Clamp CDCV hose between CDCV and air filter. Perform evaporative emission control system leak inspection. 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 passed, go to next step. If system failed, go to step  9.
  7. Remove clamp from CDCV hose. Perform evaporative emission control system leak inspection. 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 passed, go to step  10. If system failed, replace CDCV. After repair, go to step  10.
  8. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM in REMOVAL, OVERHAUL & INSTALLATION article. Remove rear seat cushion. Remove fuel pump access cover. Disconnect fuel hoses and electrical connector. Remove and check fuel tank and fuel gauge sending unit for leakage or damage. If no leaks are found, go to next step. If leak is found, repair or replace components as necessary. After repair, go to next step.
  9. Reconnect all disconnected hoses and connectors. Perform evaporative emission control system leak inspection. 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 passed, go to next step. If system still failed, locate leak and repair as necessary. After repair, go to next step.
  10. Turn ignition switch on, engine off. Using scan tool, access ECT, FTL V and IAT PIDs. PID values should be:
    • ECT - 95°F (35°C) or less.
    • FTL V - 1.3-3.75 volts or 35-85 percent fuel tank level equivalent.
    • IAT - 14-140°F (-10-60°C)

    All PIDs must be within specification to start monitoring. If any PID is out of specification, cool down engine or adjust fuel level, then go to next step. If all PIDs are within specification, go to next step.

  11. Perform EVAP System Very Small Leak Repair Verification. See DRIVE MODE 5 - EVAP SYSTEM VERY SMALL LEAK REPAIR VERIFICATION  under SELF-DIAGNOSTIC SYSTEM. Access ON BOARD SYSTEM READINESS TEST menu of GENERIC OBD II FUNCTION and check DRIVE MODE completion status. Access DIAGNOSIS MONITORING TEST RESULTS in GENERIC OBD II FUNCTIONS. Monitor TEST #10:23:00. If test result is 0 or 65535, monitoring was not implemented, go back to step  10. If test result is not 0 or 65535, monitoring has been implemented. Go to next step.
  12. Ensure test result is less than MAX value. If result is less than MAX value, go to next step. If test result is more than MAX value, replace PCM. After repair, go to next step.
  13. Cycle ignition switch from off to on. Check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If no other DTCs are present, testing is complete. If any other DTC is present, go to applicable test and repair.
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