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Home >> Mazda >> 2002 >> Protege5 Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0442: EVAP Control System, Small Leak Detected >> 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  23.
  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 damaged. If fuel filler cap is not leaking, ensure fuel filler cap is original equipment. Replace as necessary and go to step  14. If fuel filler cap is okay, go to next step.
  4. Using scan tool, perform Whole System Inspection. See WHOLE SYSTEM INSPECTION under SYSTEM LEAK INSPECTION - USING VACUUM PUMP under FUEL EVAPORATIVE SYSTEM - EXCEPT MPV in SYSTEM & COMPONENT TESTING – MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If no leaks were detected in EVAP system, go to step  14. If leak is detected, and EVAP system tester is not available, go to next step. If leak is detected, and evaporative emission tester is available, go to step  13.
  5. Using scan tool, perform Inspection From Charcoal Canister To Fuel Tank. 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  8.
    NOTE: Fuel gauge and pump are bolted together and are removed from fuel tank as an assembly.
  6. Disconnect negative battery cable. 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 fuel tank and fuel gauge sending unit are okay, go to next step. If problem is found, repair or replace as necessary. After repair, go to step  14.
    NOTE: Rollover valve is an integral part of fuel tank. If rollover valve is faulty, replace fuel tank.
  7. With fuel tank out of vehicle, check rollover valve for damage. If rollover valve is damaged, replace fuel tank. After repair, go to step  14. If rollover valve is okay, check for disconnected, incorrectly installed or cracked hoses on fuel tank and from charcoal canister to fuel tank. Repair or replace as necessary. After repair, go to step  14.
  8. 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  14.
  9. Remove catch tank and check for leaks and plugging. Catch tank is located at right side of engine compartment, next to windshield fluid reservoir. If catch tank is okay, go to next step. If catch tank is plugged or leaking, replace catch tank. After repair, go to step  14.
  10. Remove purge solenoid valve and check for leaks and damage. Purge solenoid valve is located above catch tank, at right side of engine compartment, next to windshield fluid reservoir. If purge solenoid valve is okay, go to next step. If purge solenoid valve is damaged or leaking, replace purge solenoid valve. After repair, go to step  14.
  11. Remove charcoal canister, located near fuel tank. Inspect for damage or leaks. If charcoal canister is okay, go to next step. If charcoal canister is damaged or leaking, replace charcoal canister. After repair, go to step  14.
  12. Remove CDCV and check for damage or leaks. CDCV is located next to charcoal canister. If CDCV is damaged or leaking, replace CDCV. After repair, go to step  14. If CDCV is okay, check for cracked, disconnected or improperly routed vacuum hoses between CDCV and charcoal canister. Repair as necessary. After repair, go to step  14.
  13. Check fuel filler cap for leakage 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 fuel filler cap is leaking, replace fuel filler cap. After repair, go to next step. If no leaks are found, go to next step.
  14. Turn ignition switch on, engine off. Using scan tool, monitor PID data for BARO, ECT, IAT and FTL. PID data should read BARO is 21.3 in. Hg or more, ECT is 14-71.8°F (-10-22.1°C), IAT is 14-140°F (-10-60°C) and FTL is 15-85 percent. If any signals are not within specification, go to next step. If all signals are within specification, go to step  17.
  15. Using evaporative emission system leak detector, perform EVAP 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 system fails small leak test, go to next step. If system test result is okay, EVAP system repair is complete, go to step  23.
  16. Turn ignition switch on, engine off. Using scan tool, access BARO, ECT, IAT and FTL PIDs. PID data should read:
    • BARO - 20.5 in. Hg or more.
    • ECT - 14-68°F (-10-20°C).
    • IAT - 14-140°F (-10-60°C).
    • FTL - 35-85 percent.

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

  17. Using evaporative emission system leak detector, perform EVAP 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 system test result is okay, EVAP system repair is complete, go to step  23. If EVAP system test result is not okay, go to next step.
  18. Turn ignition switch on, engine off. Using scan tool, access BARO, ECT, IAT and FTL PIDs. PID data should read:
    • BARO - 20.5 in. Hg or more.
    • ECT - 14-68°F (-10-20°C).
    • IAT - 14-140°F (-10-60°C).
    • FTL - 35-85 percent.

      If any PID value is not as specified, correct condition (e.g. cool down engine) and repeat this step. If all PID values are as specified, go to next step.

  19. Turn ignition switch on. Clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If possible to perform drive mode 4, go to step  21. If it is not possible to perform drive mode 4, go to next step.
  20. Using evaporative emission system leak detector, perform EVAP 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 system test result is okay, EVAP system repair is complete, go to step  23. If EVAP system test result is not okay, Replace PCM. After repair, go to step  23.
  21. Perform EVAP system repair verification drive mode. See DRIVE MODE 4 - EVAP SYSTEM REPAIR VERIFICATION  under SELF-DIAGNOSTIC SYSTEM. Stop vehicle and 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, repeat step  18.
  22. Using scan tool, access DIAGNOSTIC MONITORING TEST RESULTS. If reading is less than MAX value, go to next step. If reading is not as specified, replace PCM. After repair, go to next step.
  23. 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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