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Evaporative system leak inspection using leak tester

WARNING: This page is about a different car, the 2004 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.
  1. Perform the following SST  (Evaporative Emission System Tester MZ254AT3641) self-test:
    NOTE:
    • If the tester does not work correctly during the self-test, refer to the tester operators manual for more detailed self test procedures.
    1. (1) Verify that the gas cylinder valve is closed and the control valve located on the tester is in the TEST position. All tester displays should be off at this time.
    2. (2) Connect the long hose (part of SST  ) to the tester.
      Fig 1: Connecting SST Long Hose To Leak Tester
      G01012499Courtesy of MAZDA MOTORS CORP.
    3. (3) Connect the manifold assembly (part of SST  ) to the long hose as shown.
    4. (4) Open the gas cylinder valve and verify the gas cylinder regulator left gauge reads 10 to 12 psi  (preset at factory).
      • If not, refer to the tester operators manual to contact tester manufacturer.
    5. (5) Press the ON/OFF switch to turn on the SST  and make sure the left display reads 0.0. 
    6. (6) Turn the control valve on the tester to the FILL position.
    7. (7) Verify the left display reading is within 13.9 to 14.0 inches of water. 
      Fig 2: Connecting SST Manifold Assembly To Long Hose
      G01012500Courtesy of MAZDA MOTORS CORP.
      • If not, adjust the pressure using the regulator knob located on the right side of the tester.
    8. (8) Turn the control valve to TEST position and press the START switch.
    9. (9) After the 2-minute  countdown (left display) is completed, the right display shows the total pressure loss for that period. A 0.5 inch of water  loss is acceptable on the self-test.
      • If the loss is 0.5 inch or more  of water, do one or more self-tests. If the test repeatedly fails, check for leaks using the ultrasonic leak detector (part of SST  ).
  2. Press the RESET switch to set the left display reading to 0.0. 
  3. Connect the fuel cap test adapter (part of SST  ) to the manifold assembly and fuel-filler cap from the vehicle.
    • If the fuel-filler cap is not a genuine part, replace it.
  4. Connect the threaded test adapter (part of SST  ) to the manifold assembly and fuel-filler neck.
  5. Connect the WDS or equivalent to DLC-2.
  6. Turn the ignition switch to ON position (Engine OFF).
  7. Request the PCM for on-board device control (Mode 08) using the WDS or equivalent to close the change-over valve (COV) in EVAP system leak detection pump.
    NOTE:
    • The COV is closed for 10 minutes unless  the following any actions are done:
      • The engine is started.
      • The ignition switch is turned to OFF position.
    Fig 3: Connecting SST Threaded Test Adapter To Manifold Assembly And Fuel-Filler Neck
    G01012501Courtesy of MAZDA MOTORS CORP.
  8. Turn the control valve to the FILL position.
  9. Wait (maximum 40 seconds)  until the left display reads 13.5 to 14 inches of water. 
    • If the reading is slightly below, adjust it using the regulator knob.
    • If the reading is far below, the EVAP system has a large leak. Check for leaks (using the ultrasonic leak detector if necessary) and repair.
  10. Turn the control valve to the TEST position and press the START switch.
  11. After the 2-minute  countdown (left display) is completed, check the test result (the failed/passed light on the tester).
    • If the green light illuminates, the EVAP system is OK.
    • If the red light illuminates, the EVAP system has leakage. Check for leaks using the ultrasonic leak detector and repair.
  12. Close the gas cylinder valve.
  13. Turn the control valve to the FILL position.
  14. Press the ON/OFF switch to turn off the tester.
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