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Home >> Mazda >> 2003 >> 6 s, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls [Self-Diagnostics 3.0L] >> Diagnostic Tests >> DTC P0455: EVAP Control System - Large Leak Detected >> 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 related PENDING CODE or stored DTCs. If DTC is P0443 and/or P0446 are not present, go to next step. If DTC is P0443 and/or P0446 are present, go to appropriate DTC trouble shooting procedure. Refer to DIAGNOSTIC TROUBLE CODE DEFINITIONS .
  4. Classify Intermittent Concern Or Continuous 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 test result failed (Red light comes on), go to next step. If system passed (Green light comes on), intermittent concern exists. Inspect purge solenoid valve and EVAP system leak detection pump circuit for intermittent concern. Refer to INTERMITTENTS in TROUBLE SHOOTING - NO CODES article.
    5. NOTE: When fuel-filler caps other than OEM caps are attached, it is considered malfunction.
  5. Inspect Fuel Filler Cap -  Verify fuel-filler cap is not either disconnected, loose or damaged. If fuel filler cap is okay, go to next step. If fuel filler cap is not okay, retighten fuel-filler cap or replace it, if it is damaged. After repair, go to step  18.
  6. Inspect Purge Solenoid Valve For Being Stuck -  Inspect purge solenoid valve. 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  18.
  7. Inspect COV (EVAP System Leak Detection Pump) -  Perform EVAP System Leak Detection Pump Inspection. Refer to LEAK DETECTION PUMP - MAZDA6 (3.0L) under FUEL EVAPORATIVE SYSTEM - EXCEPT PROTEGE & PROTEGE5 under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If COV (EVAP leak detection pump) is okay, go to next step. If COV is faulty, replace leak detection pump. After repair, go to step  18.
    8. NOTE: If evaporative emission tester is not available, then go to step  9.
  8. Inspect EVAP Control System For Leakage Or Blockage -  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), repair or replace faulty component. After repair, go to step  18.
  9. Inspect Leakage Of Charcoal Canister To Fuel Pump For Leakage -  Disconnect fuel tank side vacuum hose at charcoal canister. Apply vacuum 0.5 in. Hg (1.7 kPa) to disconnected vacuum hose using vacuum pump. If vacuum does not hold, go to next step. If vacuum holds for minimum of 2 minutes, go to step  13.
  10. Verify Poor Connection Of Vacuum Hose -  Verify vacuum hose installation condition between fuel tank and charcoal canister. If poor connection is not present, go to next step. If poor connection is detected, reconnect vacuum hose correctly. After repair, go to step  18.
  11. Inspect Fuel Tank Installation -  Remove fuel tank. Visually inspect for damage, insufficient sealing or poorly installed fuel pump unit. If fuel tank installation is okay, go to next step. If fault is found, repair or replace fuel tank or replace seal. After repair, go to step  18.
  12. Inspect Fuel Tank -  Inspect fuel tank. If fuel tank is okay, replace vacuum hose from charcoal canister to fuel tank. After repair, go to next step. If fuel tank is faulty, replace fuel tank. After repair, go to next step.
  13. Inspect Leakage From Charcoal Canister To Purge Solenoid Valve -  Disconnect purge solenoid valve side vacuum hose at charcoal canister. Apply vacuum 1.0 in. Hg (3.3 kPa) to disconnected vacuum hose using vacuum pump. If vacuum does not hold for a minimum of 2 minutes, go to next step. If vacuum holds for a minimum of 2 minutes, go to step  18.
  14. Verify Poor Connection Of Vacuum Hose -  Verify vacuum hose installation condition between purge solenoid valve and charcoal canister. If poor connection is not present, go to next step. If a poor connection is detected, reconnect vacuum hose correctly. After repair, go to step  18.
  15. Inspect Purge Solenoid Valve For Damage Or Air Leak -  Remove purge solenoid valve and inspect for damage and air leak. 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  18.
  16. Inspect Catch Tank -  Remove catch tank and inspect for plugging, damage and pinholes 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  18.
  17. Inspect Charcoal Canister -  Remove charcoal canister and inspect for plugging, damage and pinholes. If charcoal canister is okay, go to next step. If charcoal canister is faulty, replace charcoal canister.
  18. Perform Leak Inspection -  Reconnect all disconnected connectors. 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. Is test result failed (Red light turns on), leakage still exists. Locate leak point and repair. After repair, go to next step.
  19. 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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