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Home >> Mazda >> 2003 >> Protege5 Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0442: EVAP Control System, Small Leak Detected >> 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 step  14.
  2. Verify Related Pending Code & Stored DTCs -  Turn ignition off, 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.
    NOTE: During following procedure, ensure fuel filler cap is OEM. (If fuel filler cap is not OE, it is considered a malfunction.)
  3. Inspect Fuel Filler Cap -  Ensure fuel filler cap is secure and not damaged. If fuel filler cap is okay, go to next step. If fuel filler cap is loose, not OEM or damaged, repair or replace fuel filler cap as necessary. After repair, go to step  14.
  4. Inspect Whole EVAP Control System -  Using scan tool, perform Whole System Inspection. See SYSTEM LEAK INSPECTION - USING VACUUM PUMP under FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If vacuum changes to less than specified readings and holds for 2 minutes, no leaks were detected in EVAP system. Go to step  14. If vacuum did not change to less than specified readings and hold for 2 minutes, EVAP system leak is present. If evaporative emission tester is not available, go to next step. If evaporative emission tester is available, go to step  13.
  5. Inspect Leakage Of From Charcoal Canister To Fuel Tank -  Using scan tool, perform Inspection From Charcoal Canister To Fuel Tank. See SYSTEM LEAK INSPECTION - USING VACUUM PUMP under FUEL EVAPORATIVE SYSTEM (EXCEPT MIATA & MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If leak is detected, go to next step. If vacuum changes to less than specified readings and holds for 2 minutes, no leaks were detected in EVAP system. Go to step  8.
    NOTE: During following procedure, fuel gauge and pump are bolted together and are removed from fuel tank as an assembly.
  6. Inspect Attached Accessories On Fuel Tank -  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 fuel tank or seals 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. Inspect Rollover Valve -  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. Inspect Leakage Between Charcoal Canister & 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 leak is detected, go to next step. If vacuum changes to less than specified readings and holds for 2 minutes, no leaks were detected in EVAP system. Go to step  14.
  9. Inspect Catch Tank -  Remove catch tank and check for damage, pin hole leaks and plugging using vacuum pump. 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 damaged, plugged or leaking, replace catch tank. After repair, go to step  14.
  10. Inspect Purge Solenoid Valve -  Remove purge solenoid valve and check for damage and air leaks. Purge solenoid valve is located at left side of engine compartment on firewall. 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. Inspect Charcoal Canister -  Remove charcoal canister, located near fuel tank. Inspect for damage or pinhole 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. Inspect CDCV -  Remove CDCV and check for damage or air 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. Inspect Leakage Of Evaporative Control System -  Check fuel filler cap for leakage using evaporative emission tester. See EVAPORATIVE EMISSION SYSTEM TESTER SELF TEST - PROTEGE & PROTEGE5 under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If no leak is found, go to next step. If fuel filler cap is leaking, replace fuel filler cap. After repair, go to next step.
  14. Verify Monitoring Condition For Evaporative System Test -  Turn ignition 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 step  17.

  15. Verify EVAP System Repaired -  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 - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If system test result for small leak is okay, EVAP system repair is complete, go to step  21. If EVAP system test result for small leak is not okay, go to next step.
    NOTE: During following procedure, PID readings need to be in indicated ranges to perform Drive Mode.
  16. Verify Monitoring Condition For Evaporative System Test Or Drive Mode 4 -  Turn ignition 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, take correct action (e.g. cool down engine), then repeat this step. If all PID values are as specified, go to next step.

  17. Decide On After Repair Procedure According To Repair Shop Condition -  Turn ignition on, engine off. Using scan tool, clear DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES  under SELF-DIAGNOSTIC SYSTEM. If possible to perform drive mode 4, go to step  19. If not possible to perform drive mode 4, go to next step.
  18. Verify EVAP System Repaired By Evaporative System Test -  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 - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If system test result is okay, EVAP system repair is complete. Go to step  21. If EVAP system test result failed, replace PCM. For PCM removal and installation, see POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION article. After repair, go to step  21.
  19. Monitor EVAP System By Drive Mode 4 -  Perform drive mode 4. 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  16.
  20. Verify EVAP System Repaired -  Using scan tool, access DIAGNOSTIC MONITORING TEST RESULTS. If results are less than MAX value, go to next step. If results are more than MAX value, 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.
  21. 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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