Diagnostic Procedure

STEP	INSPECTION		ACTION
1	VERIFY FREEZE FRAME DATA (MODE 2)/SNAPSHOT DATA AND DIAGNOSTIC MONITORING TEST RESULTS HAVE BEEN RECORDED Have the FREEZE FRAME DATA (Mode 2)/snapshot data and DIAGNOSTIC MONITORING TEST RESULTS (EVAP system related) been recorded?	Yes	Go to the next step.
1		No	Record the FREEZE FRAME DATA (Mode 2)/snapshot data and DIAGNOSTIC MONITORING TEST RESULTS on the repair order, then go to the next step.
2	VERIFY RELATED REPAIR INFORMATION AVAILABILITY Verify related Service Bulletins and/or on-line repair information availability. Is any related repair information available?	Yes	Perform repair or diagnosis according to the available repair information. If the vehicle is not repaired, go to the next step.
2		No	Go to the next step.
3	VERIFY RELATED PENDING CODE AND/OR DTC Switch the ignition to off, then to ON (engine off). Perform the Pending Trouble Code Access Procedure and DTC Reading Procedure. (See ON-BOARD DIAGNOSTIC TEST .) Are any other PENDING CODEs and/or DTCs present?	Yes	Go to the applicable PENDING CODE or DTC inspection. (See DTC TABLE .)
3		No	Go to the next step.
4	VERIFY DTC FOR SMALL LEAK Is the DTC P0456:00 present?	Yes	Go to Step 9.
4	VERIFY DTC FOR SMALL LEAK Is the DTC P0456:00 present?	No	Go to the next step.
5	VERIFY DTC FOR LARGE LEAK Is the DTC P0455:00 present?	Yes	Verify that the purge solenoid valve is not blocked. If the purge solenoid valve is functioning correctly and receiving engine vacuum: Go to the next step.
5	VERIFY DTC FOR LARGE LEAK Is the DTC P0455:00 present?	No	Go to the next step.
6	PRELIMINARY LEAK TEST (EXCEPT P0456:00) Perform the Evaporative Emission (EVAP) System Leak Inspection. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION .) Verify that all PIDs are within the following specifications: NOTE: To successfully perform this procedure, all PIDs must be within specification before proceeding to the next step. Select the following items from the initialization screen of the M-MDS. Select "Powertrain". Select "Fuel". Select "EVAP Test". Verify that ECT and IAT are within specification at the confirmation screen. To successfully perform this procedure, ECT and IAT must be within specification before proceeding to the next step. The fuel level must be maintained within 15 %-85 % . The PCM will cancel the EVAP test if the fuel level is lower than 15 % or higher than 85 % . Allow the M-MDS to run the EVAP test. Does the M-MDS indicate an EVAP system leak exists?	Yes	Go to the next step.
6		No	Go to Step 9.
7	PRELIMINARY LEAK TEST (EXCEPT P0456:00) Tighten the fuel-filler cap then repeat the Evaporative Emission (EVAP) System Leak Inspection using the M-MDS again. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION .) Verify that all PIDs are within the following specifications: NOTE: To successfully perform this procedure, all PIDs must be within specification before proceeding to the next step. Select the following items from the initialization screen of the M-MDS. Select "Powertrain". Select "Fuel". Select "EVAP Test". Verify that ECT and IAT are within specification at the confirmation screen. To successfully perform this procedure, ECT and IAT must be within specification before proceeding to the next step. The fuel level must be maintained within 15 %-85 % . The PCM will cancel the EVAP test if the fuel level is lower than 15 % or higher than 85 % . Allow the M-MDS to run the EVAP test. Does the M-MDS still indicate an EVAP system leak exists?	Yes	Go to the next step.
7		No	The fuel cap was not properly tightened. Go to Step 15.
8	VISUALLY INSPECT COMPONENTS FOR LEAKS (EXCEPT P0456:00) Verify that the CV solenoid valve is properly seated on the charcoal canister. Visually inspect for cut or loose connections to the fuel vapor hoses/tubes in the following locations: Charcoal canister to CV solenoid valve Charcoal canister to evaporative emission valve component Evaporative emission valve component to the fuel tank (if applicable) 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 if necessary. Afterwards, verify that the leak is repaired by repeating diagnostic Step 6. If the leak is repaired: Go to Step 15.
8		No	Go to the next step.
9	CALIBRATE LEAK TESTER FOR DIAGNOSIS Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle valve. Fig 1: Connecting EVAP Tester Hose To Control Panel Courtesy of MAZDA MOTORS CORP. Connect the EVAP Tester Hose (part of the SST ) to the SELF-TEST port located on the control panel. Hand tighten the fitting. (Do not overtighten.) Turn the control valve to the TEST position; the gauge should read 331-381 mm {13-15 in} of water. NOTE: If the gauge is not reading in this range, adjust the pressure by turning the black knob on the low pressure regulator at the nitrogen bottle. Fig 2: Turning Black Knob On Low Pressure Regulator At Nitrogen Bottle Courtesy of MAZDA MOTORS CORP. After verifying the regulator is properly calibrated, turn the control valve to the HOLD position. Verify that the gauge holds pressure and that the flow meter reads no flow. Does the gauge hold pressure and the flow meter read no flow?	Yes	Go to the next step.
9		No	Refer to the tester operator's manual for tester repair instructions.
10	PRESSURIZE EVAP SYSTEM WITH NITROGEN TO TEST FOR LEAKS Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle valve. Disconnect the evaporative hose from the intake manifold and insert SST AKS042808 into the evaporative hose. Fig 3: Disconnecting Evaporative Hose From Intake Manifold Courtesy of MAZDA MOTORS CORP. Connect the EVAP Tester Hose to SST AKS042808. Perform the PID/DATA Monitor and Record Procedure. (See ON-BOARD DIAGNOSTIC TEST .) Press the eraser icon to deselect the highlighted PIDs. Fig 4: Icon Chart Courtesy of MAZDA MOTORS CORP. Select the EVAPCP and EVAPCV PIDs, then click the tick icon. Command EVAPCP to 100 % duty cycle to open the purge solenoid valve. To open the purge solenoid valve, click the control item activate icon. Click the EVAPCP box on the left-hand side of the screen to select it. Click the control icon on the right-hand side of the screen. Click the up icon immediately below the control icon. Each click increases the duty cycle by 10 % . Continue clicking until the M-MDS shows the purge solenoid valve is open 100 % . Command EVAPCV to ON to Close the CV solenoid valve. To close the CV solenoid valve, click the control item activate icon. Click the EVAPCV box in the upper left-hand corner of the screen to select it. Click the control icon on the right-hand side of the screen. Click the up icon immediately below the control icon (the EVAPCV should now be on). Turn the control valve to the TEST position and let the system fill. A drop in the gauge pressure should be noted along with the flow meter being pegged at maximum flow for several minutes depending on how full or empty the fuel tank is, and how long it takes to completely fill and pressurize the evaporative emissions system hoses. NOTE: If the gauge and the flow meter do not settle to a measurable level after 2-3 min , then refer to the Mazda Workshop Manual to verify that the canister vent valve is properly closed. If the canister vent valve is properly closed, the EVAP system has a large leak. Does the test indicate that a leak exists?	Yes	Go to Step 13 to locate the leak.
10		No	P0442:00 or P0455:00: Go to the next step. P0456:00: Go to Step 12.
11	CHECKING SYSTEM FOR BLOCKAGE Leave the tester in the test position. Access the EVAPCV PID, command the CV solenoid valve open. To open the CV solenoid valve, click the down icon (the EVAPCV should now be off). Fig 5: Icon Chart Courtesy of MAZDA MOTORS CORP. Does the flow indicator in the flow meter immediately jump to the top?	Yes	Go to the next step
11		No	System is blocked between the intake manifold and the fuel tank pressure sensor: Locate and remove blockage then perform Step 10.
12	PRESSURIZE EVAP SYSTEM WITH NITROGEN TO TEST PURGE SOLENOID FOR LEAKAGE Reconnect the evaporative hose. Fig 6: Connecting Evaporative Hose Courtesy of MAZDA MOTORS CORP. Verify that the control valve on the panel is in the HOLD position. Remove the fuel-filler cap from the vehicle. If the fuel-filler cap is not a MAZDA part or equivalent, replace it. NOTE: INSPECT FUEL-FILLER CAP AND FILLER NECK Visually inspect for damage, insufficient sealing, rust, cracks or warps on the filler cap and filler neck. Repair or replace if necessary. Connect the receiver assembly (SST : 134-01059) to the vehicle cap test hose assembly (part of the SST ) and the fuel-filler cap from the vehicle. Fig 7: Connecting Receiver Assembly (SST 134-01059) To Vehicle Cap Test Hose Assembly Courtesy of MAZDA MOTORS CORP. Connect the cap adaptor (SST : 134-01058) to the vehicle cap test hose assembly (part of the SST ) and to the fuel-filler neck. Connect the EVAP Tester Hose (part of the SST ) to the center fitting of the vehicle cap test hose assembly (part of the SST ). Perform the PID/DATA Monitor and Record Procedure. (See ON-BOARD DIAGNOSTIC TEST .) Press the eraser icon to deselect the highlighted PIDs. Fig 8: Icon Chart Courtesy of MAZDA MOTORS CORP. Select PID EVAPCV, then click the tick icon. Command EVAPCV to ON to close the CV solenoid valve. To close the CV solenoid valve, click the control item activate icon. Click the EVAPCV box in the upper left-hand corner of the screen to select it. Click the control icon on the right-hand side of the screen. Click the up icon immediately below the control icon (the EVAPCV should now be on). Verify that the valve on the nitrogen bottle is still open. Fig 9: Identifying Valve On Nitrogen Bottle Still Open Courtesy of MAZDA MOTORS CORP. Turn the control valve to the TEST position and let the system fill. A drop in the gauge pressure should be noted along with the flow meter being pegged at maximum flow for several minutes depending on how full or empty the fuel tank is, and how long it takes to completely fill and pressurize the evaporative emissions system hoses. Does the test indicate that a leak exists?	Yes	Replace the purge solenoid valve, then go to the next step. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
12		No	Go to the next step.
13	LOCATE LEAKAGE POINT Verify that the control valve on the panel is in the HOLD position and the valve on the nitrogen bottle valve is open. Disconnect the evaporative hose from the intake manifold and insert SST AKS042808 into the evaporative hose. Fig 10: Disconnecting Evaporative Hose From Intake Manifold Courtesy of MAZDA MOTORS CORP. Connect the EVAP Tester Hose to SST AKS042808. Connect the 12 volt power connector leads on the smoke generation unit to the vehicle's battery. Make sure to connect the red lead to the positive post (+) or power, and the black lead to the vehicle's chassis ground. Fig 11: Connecting 12 Volt Power Connector Leads On Smoke Generation Unit To Vehicle's Battery Courtesy of MAZDA MOTORS CORP. Perform the PID/DATA Monitor and Record Procedure. (See ON-BOARD DIAGNOSTIC TEST .) Press the eraser icon to deselect the highlighted PIDs. Fig 12: Icon Chart Courtesy of MAZDA MOTORS CORP. Access the EVAPCP and EVAPCV PIDs, then click the tick icon. Command EVAPCP to 100 % duty cycle to open the purge solenoid valve. To open the purge solenoid valve, click the control item activate icon. Click the EVAPCP box on the left-hand side of the screen to select it. Click the control icon on the right-hand side of the screen. Click the up icon immediately below the control icon. Each click increases the duty cycle by 10 % . Continue clicking until the M-MDS shows the purge solenoid valve is open 100 % . Command EVAPCV to ON to close the CV solenoid valve. To close the CV solenoid valve, click the control item activate icon. Click the EVAPCV box in the upper left-hand corner of the screen to select it Click the control icon on the right-hand side of the screen. Click the up icon immediately below the control icon (the EVAPCV should now be on). Turn the control valve to the TEST position. Press the remote smoke trigger on the smoke generation unit and let the system fill with smoke. Fig 13: Identifying Remote Smoke Trigger Courtesy of MAZDA MOTORS CORP. NOTE: It may be necessary to lift the vehicle to provide sufficient clearance underneath to conduct a proper visual inspection of the fuel and EVAP system. NEVER depress the remote smoke trigger before opening the nitrogen tank valve and setting the tester control valve to TEST Use a 12 volt 400, 000 candle power spot light (part # 4410000-100) or equivalent to help locate the smoke. Is a leak detected?	Yes	Repair or install a new component if necessary, then go to the next step.
13		No	Check all EVAP connections. Conduct diagnosis of intermittent concerns, then go to the next step.
14	INSPECT FUEL TANK PRESSURE SENSOR Inspect the fuel tank pressure sensor. (See FUEL TANK PRESSURE SENSOR INSPECTION .) Is there any malfunction?	Yes	Replace the fuel tank pressure sensor, then go to the next step. (See FUEL TANK PRESSURE SENSOR REMOVAL/INSTALLATION .)
14		No	Go to the next step.
15	VERIFY DTC TROUBLESHOOTING COMPLETED Make sure to reconnect all disconnected connectors. Clear the DTC from the PCM memory using the M-MDS. (See AFTER REPAIR PROCEDURE .) Perform the Pending Trouble Code Access Procedure. (See ON-BOARD DIAGNOSTIC TEST .) Is the DTC P0456:00 present?	Yes	Verify that the leak is repaired by repeating diagnostic Step 10. If the leak is repaired: Go to the next step.
15		No	Verify that the leak is repaired by repeating diagnostic Step 6. If the leak is repaired: Go to the next step.
16	VERIFY AFTER REPAIR PROCEDURE Perform the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE .) Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE .)
16		No	DTC troubleshooting completed.