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Home >> Mazda >> 2002 >> Protege ES, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0455: EVAP Control System Leak Detected, Blockage Or Large 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  31.
  2. Turn ignition switch off and then on, engine off. Using scan tool, check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If DTCs P0443 or P1449 are present, diagnose and repair these DTCs first. See DTC P0443: EVAP CONTROL SYSTEM PURGE CONTROL VALVE, CIRCUIT MALFUNCTION  or DTC P1449: CANISTER DRAIN CUT VALVE (CDCV), OPEN OR SHORT  . If DTCs P0443 and P1449 are not present, go to next step.
  3. Inspect fuel filler cap. Ensure fuel filler cap is secure and not leaking. If fuel filler cap is not leaking, ensure fuel filler cap is a Mazda part. Replace as necessary and go to step  26. If fuel filler cap is okay, go to next step.
  4. Check purge solenoid valve. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If purge solenoid valve operates properly, go to next step. If purge solenoid valve does not operate properly, replace purge solenoid valve. After repair, go to step  26.
  5. Check CDCV. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If CDCV operates properly, go to next step. If CDCV does not operate properly, replace CDCV. After repair, go to step  26.
  6. If evaporative emission system leak tester is available, perform evaporative emission control system leak inspection. 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 evaporative emission system leak tester is not available, go to next step. If system passes, go to next step. If system failed, use ultrasonic leak detector (part of evaporative emission system leak tester). Locate leak at following components:
    • Catch tank
    • Charcoal canister
    • Fuel filler cap.
    • EVAP hoses and pipes.
    • Fuel tank.

    Repair or replace as necessary. After repair, go to step  26.

  7. Perform EVAP system repair verification drive mode. See DRIVE MODE 4 - EVAP SYSTEM REPAIR VERIFICATION  under SELF-DIAGNOSTIC SYSTEM. If EVAP monitor repair verification drive mode is possible to perform, go to next step. If EVAP monitor repair verification drive mode is not possible to perform, go to step  15.
  8. Turn ignition switch on. Using scan tool, monitor BARO, ECT, IAT and FTL PIDs. PID data should read as follows:
    • BARO - 20.5 in. Hg or more.
    • ECT - 14-68° F (-10-20°C).
    • IAT - 50-140°F (-10-60°C).
    • FTL - 35-85 percent.

    If any PID is not within specification, allow engine to cool down and repeat this step. If all PIDs are within specification, go to next step.

  9. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Perform EVAP system repair verification drive mode. See DRIVE MODE 4 - EVAP SYSTEM REPAIR VERIFICATION  under SELF-DIAGNOSTIC SYSTEM. Using scan tool, access PID data for CDCV and FTP. If FTP does not change, evaporative system monitoring is inoperative, go to next step. If no EVAP system leaks were detected, system is okay at this time and go to step  29. If FTP changes, but does not reach .59 in. Hg, large leak is present in EVAP system, go to step  12. If FTP reaches .59 in. Hg, but suddenly returns to atmospheric pressure, pressure in fuel tank cannot be reduced and only gas from EVAP lines can be evacuated. Check following components:
    • Rollover valve for large ventilation resistance.
    • Check valve inoperative or blocked.
    • Air filter for clogging.

    Repair or replace as necessary. If rollover valve is leaking, replace fuel tank. After repair, go to step  26.

  10. Check purge solenoid valve. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If purge solenoid valve operates properly, go to next step. If purge solenoid valve does not operate properly, replace purge solenoid valve. After repair, go to step  26.
  11. Check FTP sensor. See FUEL TANK PRESSURE SENSOR under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If FTP sensor is okay, go to next step. If FTP sensor is not okay, replace FTP sensor. After repair, go to step  26.
  12. Remove catch tank. Inspect for damage, plugging or pinhole using vacuum pump. If catch tank is okay, go to next step. If catch tank is faulty, replace catch tank. After repair, go to step  26.
  13. Remove charcoal canister. Inspect for damage or pinhole. If charcoal canister is okay, go to next step. If charcoal canister is faulty, replace charcoal canister. After repair, go to step  26.
  14. Check CDCV. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If CDCV operates properly, go to next step. If CDCV does not operate properly, replace CDCV. After repair, go to step  26.
  15. Using scan tool and vacuum pump, perform Whole System Inspection. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If system does not hold vacuum, go to next step. If system holds vacuum, no leaks are present, system is okay at this time, go to step  26.
  16. Check FTP sensor. See FUEL TANK PRESSURE SENSOR under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If FTP sensor is okay, go to next step. If FTP sensor is not okay, replace FTP sensor. After repair, go to step  26.
  17. Using scan tool, perform EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION CHECK FROM CHARCOAL CANISTER TO FUEL TANK. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If system test result is okay, EVAP system repair is complete, go to step  21. If EVAP system test result is not okay, go to next step.
  18. Inspect fuel tank and fuel gauge sending unit for leakage or damage. Repair or replace as necessary. After repair, go to step  26. If fuel tank and fuel gauge sending unit are okay, go to next step.
  19. Check fuel shut off valve. See SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If valve is okay, go to next step. If valve is faulty, replace fuel tank. Go to step  26.
    NOTE: Rollover valve is an integral part of fuel tank. If rollover valve is faulty, replace fuel tank.
  20. Inspect rollover valve. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If rollover valve is not operating properly, replace fuel tank. After repair, go to step  26. If rollover valve is okay, check for disconnected, incorrectly installed or cracked hoses at following components:
    • Charcoal canister.
    • Fuel tank (including fuel shut-off and rollover valves).
    • FTP sensor.

    Repair or replace as necessary. After repair, go to step  26.

  21. Connect scan tool. Perform Evaporative Emission Control System Inspection From Charcoal Canister To Purge Solenoid Valve. See SYSTEM LEAK INSPECTION - USING VACUUM PUMP under FUEL EVAPORATIVE SYSTEM - EXCEPT MPV in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If leak is detected go to next step. If no leak is detected, go to step  26.
  22. Remove catch tank. Check for damage or plugging using vacuum pump. If catch tank is okay, go to next step. If catch tank is faulty, replace catch tank. After repair, go to step  26.
  23. Check purge solenoid valve. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If purge solenoid valve is okay, go to next step. If purge solenoid valve is faulty, replace purge solenoid valve. After repair, go to step  26.
  24. Remove charcoal canister located next to fuel tank. Inspect for damage, pin hole or plugging. If charcoal canister is okay, go to next step. If charcoal canister is faulty, replace charcoal canister. After repair, go to step  26.
  25. Check CDCV. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If CDCV operates properly, go to next step. If CDCV does not operate properly, replace CDCV. After repair, go to next step.
  26. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Review steps necessary to perform EVAP system repair verification drive mode. See DRIVE MODE 4 - EVAP SYSTEM REPAIR VERIFICATION  under SELF-DIAGNOSTIC SYSTEM. If EVAP monitor repair verification drive mode is possible, go to next step. If EVAP monitor repair verification drive mode is not possible, go to step  30.
  27. Turn ignition switch on. Using scan tool, monitor BARO, ECT, IAT and FTL PIDs. PID data should read as follows:
    • BARO - 20.5 in. Hg or more.
    • ECT - 14-68° F (-10-20°C).
    • IAT - 50-140°F (-10-60°C).
    • FTL - 35-85 percent.

    If any PID is not within specification, allow engine to cool down and repeat this step. If all PIDs are within specification, go to next step.

  28. Perform EVAP system repair verification drive mode. See DRIVE MODE 4 - EVAP SYSTEM REPAIR VERIFICATION  under SELF-DIAGNOSTIC SYSTEM. Access ON BOARD SYSTEM READINESS TEST menu of GENERIC OBD II FUNCTION and check DRIVE MODE completion status. If EVAPORATIVE PURGE SYSTEM monitor is complete, go to next step. If EVAPORATIVE PURGE SYSTEM monitor is not complete, go back to step  27.
  29. Using scan tool, access DIAGNOSIS MONITORING TEST RESULTS in GENERIC OBD II FUNCTIONS. Monitor TEST #10:22:00. If test result is less than MAX value, go to step  31. If test result in not less than MAX value, replace PCM. After repair, go to step  31.
  30. Using scan tool and vacuum pump, perform Whole System Inspection. See FUEL EVAPORATIVE SYSTEM - EXCEPT MPV under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If system does not hold vacuum, replace PCM. After repair, go to next step. If system holds vacuum, no leaks are present, system is okay at this time, go to next step.
  31. 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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