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Diagnostic Procedures

WARNING: This page is about a different car, the 2003 Mazda MPV and 2002 Mazda MPV. However, it is still accessible from the selected car via links, so may be relevant.
  1. Record freeze frame data. Check for service bulletins and on-line information. Repair as necessary. After repair, go to next step.
  2. Verify Related Pending Code Or Stored DTCs -  Turn ignition on, engine off. Check other related DTCs. If other DTCs are not present, go to next step. If DTCs other than P0442 are present, repair those DTCs first. Refer to DIAGNOSTIC TROUBLE CODE IDENTIFICATION .
  3. Classify Intermittent Concern Or Continuous Concern -  Perform EVAP system leak inspection. See EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER article. If system test result failed (Red light on), go to next step. If system test result passed (Green light on), problem is intermittent. Check purge solenoid valve and EVAP system leak detection pump circuit for intermittent concern. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES article.
  4. Locate Leak Point -  Locate leak using ultrasonic leak detector. Inspect following areas:
    • Catch tank.
    • Charcoal canister.
    • EVAP system hoses and pipes.
    • Fuel filler cap.
    • Fuel tank.

    If no leak is found, go to next step. If leakage is found, repair or replace part as necessary. After repair, go to step  9.

  5. Inspect Purge Solenoid Valve -  Check if purge solenoid valve is stuck closed. See FUEL EVAPORATIVE SYSTEM (MPV) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - MAZDA6, MIATA, MPV, PROTEGE & PROTEGE5 article. If purge solenoid valve is okay, go to next step. If purge solenoid valve is not okay, replace purge solenoid valve. After repair, go to step  9.
  6. Inspect EVAP System Leak Detection Pump -  Connect all disconnected connectors and hoses. Place clamp on hose between EVAP system leak detection pump and air filter. 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 test result passed (Green light on), go to next step. If test result failed (Red light on), go to step  8.
  7. Confirm EVAP System Leak Detection Pump Leakage -  Remove clamp. 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 test result passed (Green light on), go to next step. If test result failed (Red light on), replace EVAP system leak detection pump. After repair, go to step  9.
  8. Inspect Fuel Pump Unit Installation -  Inspect fuel pump unit installation. Remove fuel tank. Check for damage, insufficient sealing or incorrect installation. If any problems are found, repair as necessary. After repair, go to next step. If no problem is found, go to next step.
  9. Perform Leak Inspection -  Reconnect all disconnected connectors and hoses. 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 test result failed (Red light on), locate leak and repair. After repair, go to next step. If test result passed (Green light on), go to next step.
  10. 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, go to applicable test and repair.
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