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Home >> Mazda >> 2003 >> 6 s, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls [Self-Diagnostics 3.0L] >> Diagnostic Tests >> DTC P0441: EVAP Control System - Incorrect Purge Flow >> Diagnostic Procedure

Diagnostic Procedure

  1. If FREEZE FRAME DATA has been recorded, go to next step. If FREEZE FRAME DATA has not been recorded, record FREEZE FRAME DATA. Go to next step.
  2. Verify Related Repair Information Availability -  Check for related Service Bulletins and/or on-line repair information availability. If any related repair information is available, perform repair or diagnosis according to available repair information. If vehicle is not repaired, go to next step. If related repair information is not available, go to next step.
  3. Verify Related Pending Code Or Stored DTCs -  Turn ignition off, then on (engine off). Verify pending code or stored DTCs using WDS or equivalent. If no other DTCs are present, go to next step. If DTC P0443 is present, go to DTC P0443: EVAPORATIVE EMISSION CONTROL SYSTEM PURGE SOLENOID VALVE CIRCUIT - MALFUNCTION .
  4. Determine If Leak Concern Or Blockage Concern -  Perform Evaporative System Leak Inspection. Refer to EVAP SYSTEM TEST under FUEL EVAPORATIVE SYSTEM - EXCEPT PROTEGE & PROTEGE5 under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If system test passes (Green light comes on), go to next step. If system test failed (Red light comes on), go to step  6.
  5. Inspect Purge Solenoid Valve -  Perform Purge Solenoid Valve Inspection. Refer to PURGE SOLENOID VALVE under RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If purge solenoid valve is okay, check following parts for clogging.
    • Catch tank
    • Charcoal canister
    • Vacuum hoses between intake manifold and charcoal canister
    Repair or replace faulty part. After repair, go to step  11. If purge solenoid valve is faulty, replace purge solenoid valve. After repair, go to step  11.
  6. Locate Leak Point -  Check following for leakage using Ultrasonic leak detector.
    • Catch tank
    • Charcoal canister
    • EVAP hoses and pipes
    • Fuel filler cap
    • Fuel tank
    If no leakage is found, go to next step. If leakage is found, repair leakage or replace part. After repair, go to step  10.
  7. Inspect EVAP System Leak Detection Pump -  Connect all disconnected connectors and hoses. Place clamp on EVAP system leak detection pump hose between EVAP system leak detection pump and air filter. Perform Evaporative System Leak Inspection. Refer to EVAP SYSTEM TEST under FUEL EVAPORATIVE SYSTEM - EXCEPT PROTEGE & PROTEGE5 under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If test result passed (Green light comes on), go to next step. If test result failed (Red light on), go to step  9.
  8. Confirm EVAP System Leak Detection Pump Leakage -  Remove clamp. Perform Evaporative System Leak Inspection. If test result passed (Green light on), go to next step. If test result failed (Red light on), replace EVAP system leak detection pump. After repair, go to step  11.
  9. Inspect Fuel Tank Installation -  Remove fuel tank. Visually inspect for damage, insufficient sealing or poorly installed pump unit. If fuel tank installation is okay, go to next step. If any malfunction is present, repair or replace fuel tank or seal. After repair, go to next step.
  10. Perform Leak Inspection -  Connect all disconnected connectors and hoses. Perform Evaporative System Leak Inspection. Refer to EVAP SYSTEM TEST under FUEL EVAPORATIVE SYSTEM - EXCEPT PROTEGE & PROTEGE5 under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If test result failed (Red light comes on), leakage still exists. Locate leak point and repair. After repair, go to next step. If test result passed (Green light comes on), go to next step.
  11. Verify Trouble Shooting Of DTC P0441 Is Completed -  Start engine and let it idle. Clear DTC using WDS or equivalent. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Turn ignition off. Perform MODE 4 - EVAP SYSTEM REPAIR VERIFICATION DRIVE MODE . If PENDING CODE of same DTC is not present, go to next step. If PENDING CODE of same DTC is present, replace PCM. For PCM removal and installation, see POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article. After repair, go to next step.
  12. Verify After Repair Procedure -  Using scan tool, perform After Repair Procedure. See AFTER REPAIR PROCEDURE . If any DTCs are present, go to appropriate DTC inspection. Refer to DIAGNOSTIC TROUBLE CODE DEFINITIONS . If no DTCs are present, trouble shooting is complete.
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