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Evaporative Emission (EVAP) Monitor And System Malfunction

EVAPORATIVE EMISSION (EVAP) MONITOR AND SYSTEM MALFUNCTION DETECTION CONDITIONS AND POSSIBLE CAUSES

DTC P0442 EVAPORATIVE EMISSION (EVAP) MONITOR AND SYSTEM MALFUNCTION
DETECTION CONDITION 
  • P0442 indicates a leak has been detected as small as 1 mm (0.04 inch) in the evaporative (EVAP) emission canister purge valve solenoid system when there is less than 0.625 kPa (2.5 in-H2 O) bleed-up over 15 seconds at 75% fuel fill. Bleed-up and evaluation time vary as a function of fuel fill level. Vapor generation limit is more than 0.625 kPa (2.5 in-H2 O) over 120 seconds.
POSSIBLE CAUSE 
  • After-market EVAP hardware (such as fuel filler cap) non-conforming to required specifications
  • Small holes or cuts in fuel vapor hoses/tubes
  • Canister vent solenoid stays partially open on closed command
  • Damaged, cross-threaded or loosely installed fuel filler cap
  • Loose fuel vapor hose/tube connections to EVAP system components
  • EVAP system component seals leaking (EVAP canister purge valve, fuel tank pressure sensor, canister vent solenoid, fuel vapor control valve tube assembly or fuel vapor vent valve assembly)
HINT 
EVAPORATIVE EMISSION (EVAP) MONITOR AND SYSTEM MALFUNCTION DIAGNOSTIC PROCEDURE

DTC P0442 EVAPORATIVE EMISSION (EVAP) MONITOR AND SYSTEM MALFUNCTION
STEP INSPECTION ACTION
1
  • Was the PCM quick test performed?
 Yes Go to next step.
No Perform PCM quick test. See PCM QUICK TEST .
2 VISUALLY INSPECT THE COMPONENTS FOR SMALL LEAKS
  • Check for presence of fuel filler cap. Do not tighten or check for correct installation at this time.
  • Verify that the canister vent (CV) solenoid is properly seated on the EVAP canister.
  • Visually inspect for cut or loose connections to fuel vapor hoses/tubes in following locations:
    • EVAP canister to EVAP canister purge valve
    • EVAP canister to evaporative emission valve assembly
    • Evaporative emission valve tube assembly to fuel tank
  • Check for fuel filler pipe damage.
  • Is a concern with a hose, tube, connection, or valve visually evident? 
 Yes Repair or install a new component as necessary.
Go to step 10.
No Go to next step.
3 CHECK FOR SMALL SYSTEM LEAKS FROM THE EVAP TEST PORT
 Yes Go to next step.
No Go to step 5.
4 CHECK FOR SMALL LEAKS AT FUEL FILLER CAP AND EVAPORATIVE TEST PORT
  • Connect the EVAP system leak tester to the fuel filler pipe.
  • Key on, engine off (KOEO).
  • Using IDS or equivalent tester, select Diagnostic Data Link.
  • Select PCM.
  • Select Active Command Modes.
  • Select Output Test Mode.
  • Close EVAP canister vent (CV) solenoid using EVAPCV PID.
  • Pressurize the EVAP system to 3.48 kPa (14 in-H2 O).
  • Using the ultrasonic leak detector, check for leaks around the fuel filler cap and the evaporative test port.
  • Is a leak detected? 
 Yes Repair or install new component as necessary.
Go to step 9.
No Remove the leak tester.
Install the fuel filler cap.
Go to step 11.
5 VISUALLY INSPECT THE FUEL FILLER CAP
  • Visually inspect the fuel filler cap for damage.
  • Is the fuel filler cap damaged? 
 Yes Install a new fuel filler cap.
Go to step 10.
No Go to next step.
6 CHECK FOR SMALL LEAK WITH TESTER SET AT FILL POSITION
  • Key on, engine off (KOEO).
  • Using IDS or equivalent tester, select Diagnostic Data Link.
  • Select PCM.
  • Select Active Command Modes.
  • Select Output Test Mode.
  • Close EVAP canister vent (CV) solenoid using EVAPCV PID.
  • Pressurize EVAP system to 3.48 kPa (14 in-H2 O).
  • Does the pressure hold between 3.43 and 3.53 kPa (13.80 and 14.20 in-H 2  O)? 
 Yes Go to next step.
No Go to step 8.
7 CHECK FOR LEAKS IN THE COMPLETE EVAP SYSTEM
  • Verify EVAP canister vent (CV) solenoid is closed.
  • Verify system is pressurized to 3.48 kPa (14 in-H2 O).
  • Using the ultrasonic leak detector, check the following EVAP system locations:
    • EVAP return tube to EVAP canister purge valve
    • EVAP canister purge valve to EVAP canister
    • canister vent solenoid assembly
    • EVAP canister
    • canister vent solenoid assembly to fuel tank
    • Fuel filler cap and fuel filler pipe
  • Is a leak detected? 
 Yes Repair or install new component as necessary.
Go to step 10.
No Discontinue pressurizing the system.
Go to next step.
8 CHECK FOR SMALL LEAK FROM THE EVAP RETURN TUBE TO THE EVAP CANISTER
G04929019Courtesy of MAZDA MOTORS CORP.

  • Disconnect the fuel tank vapor tube at the fuel tank locations. Plug the openings in the tubes.
  • Key on, engine off (KOEO).
  • Close EVAP canister vent (CV) solenoid by accessing Output Test Mode.
  • Pressurize the EVAP system to 3.48 kPa (14 in-H2 O).
  • Using the ultrasonic leak detector, check the EVAP system from the intake manifold to the EVAP canister vent solenoid.
  • Is a leak detected? 
 Yes Repair or install new component as necessary.
Go to step 10.
No Discontinue pressurizing the system.
Open the canister vent solenoid.
Go to next step.
9 CHECK FOR SMALL LEAK BETWEEN FUEL TANK VAPOR TUBE AND FUEL TANK FILLER PIPE
  • Transfer the plug from the fuel vapor tee to the fuel tank vapor tube.
  • Pressurize EVAP system to 3.48 kPa (14 in-H2 O).
  • Using the ultrasonic leak detector, check the fuel tank vapor tube to the fuel tank for leaks. Check the fuel tank pressure sensor, fuel tank vapor tube and the fuel filler pipe.
  • Is a leak detected? 
 Yes Repair or install new component.
Go to next step.
No Reconnect the fuel vapor tube to the fuel vapor tee.
Go to step 11.
10 EVAP SYSTEM LEAK TEST
 Yes Go to step 12 to verify repair.
No Leakage still exists.
Locate leak point and repair.
Repeat this step.
11 DRIVE CYCLE
  • Connect all disconnected connectors.
  • Clear DTCs from PCM memory using IDS or equivalent tester.
  • Perform EVAP system monitor drive cycle. See DRIVE CYCLES .
  • Retrieve pending code.
  • Is same DTC present? 
 Yes Replace PCM.
See POWERTRAIN CONTROL MODULE (PCM) REMOVAL / INSTALLATION .
Go to next step.
No Go to next step.
12 VERIFY REPAIR
  • Perform PCM Quick Test.
  • Is any DTC present? 
 Yes Go to applicable DTC inspection. See DIAGNOSTIC TROUBLE CODE (DTC) INDEX - POWERTRAIN CONTROL MODULE (PCM) .
No Troubleshooting is complete.
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