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Home >> Mazda >> 2003 >> Protege ES, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0455: EVAP Control System Leak Detected - Blockage Or Large Leak >> Diagnostic Procedure

Diagnostic Procedure

  1. Verify Related Repair Information Availability -  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 next step.
  2. Verify Related Pending Code & Stored DTCs -  Turn ignition off and then on, engine off. Using scan tool, check for pending and related 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  and DTC P1449: CANISTER DRAIN CUT VALVE (CDCV) - OPEN OR SHORT  . If DTCs P0443 and P1449 are not present, go to next step.
    NOTE: When fuel filler cap other than OEM cap is attached, it is considered a malfunction.
  3. Inspect Fuel Filler Cap -  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 OEM part. Replace as necessary and go to step  26. If fuel filler cap is okay, go to next step.
  4. Inspect Purge Solenoid Valve Stuck -  Check purge solenoid valve. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 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.
  5. Inspect CDCV Stuck -  Check CDCV. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If CDCV is okay, go to next step. If CDCV is faulty, replace CDCV. After repair, go to step  26.
  6. Classify Evaporative Emission Control System For Leakage Or Blockage -  Perform evaporative emission control system leak inspection. If evaporative emission tester is not available, go to next step. If evaporative emission system leak tester is available, refer to FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If system passed (Green light is on), go to next step. If system failed (Red light is on), use ultrasonic leak detector (part of evaporative emission tester). Locate leak at following components:
    • Catch tank.
    • Charcoal canister.
    • EVAP hoses and pipes.
    • Fuel filler cap.
    • Fuel tank.

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

  7. Verify Repair Shop Condition -  Perform EVAP system repair verification drive mode. See MODE 4 - EVAP SYSTEM REPAIR VERIFICATION DRIVE MODE  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. Verify Monitoring Condition For Drive Mode 4 -  Turn ignition on. Using scan tool, monitor BARO, ECT, IAT and FTL PIDs. Ensure following conditions are met:
    • BARO: 20.5 in. Hg (69.7 kPa) 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 procedure. If all PIDs are within specification, go to next step.

  9. Monitor EVAP System By Drive Mode 4 -  Using scan tool, clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Perform EVAP system repair verification drive mode and verify that CDCV and FTP graphs. See MODE 4 - EVAP SYSTEM REPAIR VERIFICATION DRIVE MODE  under SELF-DIAGNOSTIC SYSTEM. Using scan tool, access PID data for CDCV and FTP. If problem is detected and FTP does not change, evaporative system monitoring is inoperative, go to next step. 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 drawn. Check following components:
    • Clogged Air filter.
    • Inoperative or blocked check valve.
    • Rollover valve for large ventilation resistance.

    Repair or replace as necessary. After repair, go to step  26. If no EVAP system leaks were detected, system is okay at this time. Go to step  29.

  10. Inspect Purge Solenoid Valve Operation -  Check purge solenoid valve. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 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.
  11. Inspect Fuel Tank Pressure Sensor -  Check FTP sensor. See FUEL TANK PRESSURE SENSOR under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If FTP sensor is okay, go to next step. If FTP sensor is faulty, replace FTP sensor. After repair, go to step  26.
  12. Inspect Catch Tank -  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. Inspect Charcoal Canister -  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. Inspect CDCV Operation -  Check CDCV. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If CDCV is okay, go to next step. If CDCV is faulty, replace CDCV. After repair, go to step  26.
  15. Inspect Whole System Of EVAP Control System -  Perform evaporative system leak inspection using vacuum pump, whole system inspection. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If vacuum reading does not change to less than specification and hold for at least 2 minutes, go to next step. If vacuum reading changes to less than specification and holds for at least 2 minutes, problem is intermittent. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES article.
  16. Inspect Fuel Tank Pressure Sensor -  Check FTP sensor. See FUEL TANK PRESSURE SENSOR under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If FTP sensor is okay, go to next step. If FTP sensor is faulty, replace FTP sensor. After repair, go to step  26.
  17. Inspect Leakage From Charcoal Canister To Fuel Tank -  Perform evaporative emission control system inspection. Check from charcoal canister to fuel tank. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If vacuum reading does not change to less than specification and hold for at least 2 minutes, go to next step. If vacuum reading changes to less than specification and holds for at least 2 minutes, go to step  21.
  18. Inspect Attached Accessories On Fuel Tank -  Remove fuel tank and check for insufficient sealing, damage or poorly attached accessories, such as fuel gauge sending unit. Repair or replace fuel tank or seal as necessary. After repair, go to step  26. If fuel tank and accessories are okay, go to next step.
  19. Inspect Fuel Shut Off Valve -  Check fuel shut off valve. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If fuel shut off valve is okay, go to next step. If fuel shut off valve is faulty, replace fuel tank. After repair, 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 -  Inspect rollover valve for ventilation. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If rollover valve is faulty, 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. Inspect Leakage From Charcoal Canister To Purge Solenoid Valve -  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 MIATA & MPV in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If vacuum reading does not change to less than specification and hold for at least 2 minutes, go to next step. If vacuum reading changes to less than specification and holds for at least 2 minutes, go to step  26.
  22. Inspect Catch Tank -  Remove catch tank located at right rear of engine compartment. 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. Inspect Purge Solenoid Valve Operation -  Check purge solenoid valve. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 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. Inspect Charcoal Canister -  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. Inspect CDCV Operation -  Check CDCV located by charcoal canister. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If CDCV is okay, go to next step. If CDCV is faulty, replace CDCV. After repair, go to next step.
  26. Decide On After Repair Procedure According To Repair Shop Condition -  Using scan tool, clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. Review steps necessary to perform EVAP system repair verification drive mode. See MODE 4 - EVAP SYSTEM REPAIR VERIFICATION DRIVE MODE  under SELF-DIAGNOSTIC SYSTEM. If EVAP monitor repair verification drive mode is possible at repair shop, go to next step. If EVAP monitor repair verification drive mode is not possible at repair shop, go to step  30.
  27. Verify Monitoring Condition For Evaporative System Test Or Drive Mode 4 -  Turn ignition on, engine off. Using scan tool, monitor BARO, ECT, IAT and FTL PIDs. PID data should read as follows:
    • BARO: 20.5 in. Hg (69.7 kPa) 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. Monitor EVAP System By Drive Mode 4 -  Perform EVAP system repair verification drive mode. See MODE 4 - EVAP SYSTEM REPAIR VERIFICATION DRIVE MODE  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 has been monitored, go to next step. If EVAPORATIVE PURGE SYSTEM has not been monitored, go back to step  27.
  29. Verify EVAP System Repaired -  Using scan tool, access DIAGNOSIS MONITORING TEST RESULTS in GENERIC OBD II FUNCTIONS. Verify TEST ID 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. Inspect Whole EVAP Control System -  Using scan tool and vacuum pump, perform Whole System Inspection. See FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If vacuum reading does not change to less than specification and hold for at least 2 minutes, replace PCM. For PCM removal and installation, see POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION article. After repair, go to next step. If vacuum reading changes to less than specification and holds for at least 2 minutes, go to next step.
  31. Verify After Repair Procedure -  Using scan tool, perform After Repair Procedure. See AFTER REPAIR PROCEDURE . If no other DTCs are present, testing is complete. If any other DTC is present, follow appropriate DTC diagnostic procedure. See DIAGNOSTIC TROUBLE CODE DEFINITIONS .
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