01-002-18-3417

Technical
Service Bulletin
Mazda North American Operations
Irvine, CA 92618-2922
Subject:
MULTI-MODEL - DETERMINING EVAPORATIVE SYSTEM LEAK
LOCATION FOR DTCs P0441 / P0442 / P0455 / P0456
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted below in Red.
Previously Issued TSBs:
Date(s) Issued
01-023/10
10/15/10 and 04/16/10
01-021/09
06/16/09
APPLICABLE MODEL(S) / VINS
2006-2015 MX-5
2007-2010 Mazdaspeed3 2006-2007 Mazdaspeed6
2007-2010 CX-7
2006-2010 Mazda5
2004-2010 Mazda3 2003-2010 Mazda6
DESCRIPTION
Some vehicles may have a MIL illumination with DTC’s P0441, P0442, P0455, or P0456 stored in memory.
To determine the location of the evaporative system leak, follow the repair procedure below.
P0441 - Evaporative emission control system incorrect purge flow
P0442 - EVAP system leak detected (small leak)
P0455 - EVAP system leak detected (gross leak)
P0456 - EVAP system leak detected (very small leak)
NOTE:



P0441 is a DTC for purge flow, however, it can be stored when evaporative emissions are
leaking from the fuel filler cap.
Evaporative emissions leak from the fuel filler cap when the cap is not closed properly after
refueling.
When diagnosing an evaporative emissions leak from the fuel filler cap, DO NOT TOUCH the
fuel filler cap.
Page 1 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
REPAIR PROCEDURE
Step
Inspection
Result
Action
Check if the EVAP system leak DTC is stored by any Yes Troubleshoot the stored DTC(s) according
other cause.
to the appropriate MGSS online
Are any of the DTCs below stored?
instructions or Workshop Manual.
1
- P0442: Purge valve malfunction
- P2177 / P2178 / P2187 / P2188 / P0171 / P0172:
Fuel system malfunction.
No Go to the next step.
Page 2 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
Perform inspection for leakage from fuel filler cap:
Connect Mazda Modular Diagnostic System (MMDS) and perform EVAP test (KOEO).
NOTE: EVAP test (KOEO) will finish in approx. two
(2) minutes if the fuel tank is nearly full. In this
case, perform the EVAP test (KOEO) again.
While performing EVAP test (KOEO), use an
Ultrasonic Leak Detector Kit and check for leakage
from fuel filler cap.
Yes Go to the next step.
2
Is EVAP leakage found from fuel filler cap?
3 Take action based on the affected model.
No Go to Step 6.
N/A 2006-2007 MX-5 (VIN:
JM1NC******111723 - 125568)
2007 CX-7 (VIN: JM3ER******100057 128616)
Refer to TSB 01-040/09 (MIL ILLUMINATED
- P0455 SET) and perform the repair, then
go to the next step.
2004-2009 Mazda3
2007-2009 Mazdaspeed3
2006-2009 Mazda5
If the fuel cap is not a modified (improved)
part, replace it with a modified part
according to TSB 01-020/10 (LOOSE FUEL
FILLER CAP WITH DTC P0442, P0455 AND
P0456), then go to the next step.
Models other than above:
Go to the next step.
Page 3 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
4
Last Issued: 01/30/2018
Check the fuel filler cap, pipe and neck.
How is the condition of the fuel filler cap and pipe?
Perform inspection for leakage from fuel filler cap:
Connect Mazda Modular Diagnostic System (MMDS) and perform EVAP test (KOEO).
NOTE: EVAP test (KOEO) will finish in approx. two
(2) minutes if the fuel tank is nearly full. In this
case, perform the EVAP test (KOEO) again.
While performing EVAP test (KOEO), use an
Ultrasonic Leak Detector Kit and check for leakage
from fuel filler cap.
N/A Loose filler cap:
Tighten the filler cap, then go to the next
step.
Foreign material, damage and/or rust on
threads:
Remove the foreign material.
If the threads are damaged or rusted,
replace it, then go to the next step.
No trouble found:
Go to the next step.
Yes If the cap and/or filler pipe has not been
replaced, repace them with modified
(improved) parts, then perform this step
again.
5
Is EVAP leakage found from fuel filler cap?
No Go to the next step.
Check EVAP leak from other than fuel filler cap/filler Yes Go to the next step.
neck.
6 Connect Mazda Modular Diagnostic System (MMDS) and perform EVAP test (KOEO).
Is any EVAP leak detected?
No Go to Step 11.
Page 4 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
Check gas-tightening of purge valve referring to the Yes Both conditions (a and b) are met.
“System Structure” below.
Go to Step 9.
NOTE: In prior, perform “Vacuum Pump Leak Test”
and verify the function of the vacuum pump
tester.
1. Disconnect purge control valve vacuum tube at
location (K) below, then connect vacuum pump to
the disconnected tube using appropriate generic
adapter.
7 NOTE: DO NOT disconnect to the charcoal canister
side (C).
2. Check if both vacuum (a and b below) can be held
between locations (K and D).
a. Apply 60 kPa {18 inHg} of vacuum and verify it is
within 60 kPa – 30 kPa {18 inHg - 9 inHg} when
checked ten (10) seconds later.
b. Apply 10 kPa {3 inHg} of vacuum and verify it is
within 10 kPa – 5 kPa {3 inHg - 2 inHg} when
checked ten (10) seconds later.
No Neither conditions (a or b) are met.
Replace purge solenoid valve (D) with a
new part according to the appropriate
MGSS online instructions or Workshop
Manual (section 01-16 PURGE SOLENOID
VALVE REMOVAL/INSTALLATION), then go
to the next step.
System Structure:
Page 5 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
A - EVAP System Leak Detection Pump G - PCV Valve
B - Air Filter
H - Rollover Valve
C - Charcoal Canister
I - Fuel Shut-Off Valve
D - Purge Solenoid Valve
J - Fuel Filler Cap
E - Check Valve - (DISI Engine only)
K - Insert Generic Adapter (Purge Side)
F - EGR Valve
---
Check EVAP leak from other locations. Yes Go to the next step.
Connect Mazda Modular Diagnostic
8 System (M-MDS) and perform EVAP
test (KOEO).
Is any EVAP leak detected?
No Repair complete.
Verify the point of EVAP leakage.
Yes Fix the leak, then go to the next step.
Disconnect vacuum tube between
purge solenoid valve and canister.
Connect Smoke Tester to canister side,
9 then perform the test.
NOTE: Refer to “EVAP System Leak
Detection Using Smoke Tester” for
precaution.
Is the EVAP leak point verified?
No You may not be able to duplicate the trouble. Go back to
Step 6.
Check EVAP leak from other locations. Yes EVAP leak from other location is possible. Go back to Step 9.
Connect Mazda Modular Diagnostic
10 System (M-MDS) and perform EVAP
test (KOEO).
Is any EVAP leak detected?
No Repair complete.
Check if EVAP system leak DTC is
Yes Go to the next step.
stored by malfunction of purge
11 solenoid valve.
Was DTC P0441 stored at the
beginning?
No Go to Step 15.
Page 6 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
Check gas-tightening of purge valve
Yes Both conditions (a and b) are met.
referring to the “System Structure”
Go to the next step.
below.
1. Disconnect purge control valve
vacuum tube, then connect vacuum
pump using appropriate generic
adapter at location (K) (intake manifold
side).
NOTE: DO NOT disconnect to the
charcoal canister side (C).
12 2. Check if both vacuum (a and b
below) can be held between locations
(K and D).
a. Apply 60 kPa {18 inHg} of vacuum
and verify it is within 60 kPa – 30 kPa
{18 inHg - 9 inHg} when checked ten
(10) seconds later.
b. Apply 10 kPa {3 inHg} of vacuum and
verify it is within 10 kPa – 5 kPa {3 inHg
- 2 inHg} when checked ten (10)
seconds later.
No Neither conditions (a or b) are met.
Replace purge solenoid valve (D) with a new part according
to the appropriate MGSS online instructions or Workshop
Manual (section 01-16 PURGE SOLENOID VALVE
REMOVAL/INSTALLATION).
System Structure:
Page 7 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
A - EVAP System Leak Detection Pump G - PCV Valve
B - Air Filter
H - Rollover Valve
C - Charcoal Canister
I - Fuel Shut-Off Valve
D - Purge Solenoid Valve
J - Fuel Filler Cap
E - Check Valve - (DISI Engine only)
K - Insert Generic Adapter (Purge Side)
F - EGR Valve
---
Check if purge solenoid valve is stuck closed.
Yes Replace purge solenoid valve with a new part
a. Re-connect intake manifold side vacuum hose
according to the appropriate MGSS online
previously disconnected.
instructions or Workshop Manual (section 01-16
13 b. Connect M-MDS, then perform KOER (Self Test)
PURGE SOLENOID VALVE
for purge flow.
REMOVAL/INSTALLATION), then perform KOER
Is the result of KOER (Self Test) fail (DTC P0441 is
(Self Test) for purge flow and verify the purge
retrieved)?
valve is working properly.
No Go to the next step.
Check EVAP leak from other locations.
Yes Trouble is duplicated. It may be able to detect
Connect Mazda Modular Diagnostic System (Mwith smoke tester. Go back to Step 9.
14
MDS) and perform EVAP test (KOEO).
Is any EVAP leak detected?
No Repair complete.
Verify the point of EVAP leakage.
Yes Go to the next step.
Disconnect vacuum tube between purge solenoid
valve and canister.
(A) Connect Smoke Tester to canister side, then
apply pressure without smoke.
15
(B) Connect Smoke Tester to purge solenoid side,
then apply pressure without smoke.
NOTE: Refer to “EVAP System Leak Detection
Using Smoke Tester” for precaution.
Is the pressure retained on both tests (A B)?
No Trouble is duplicated. It may be able to detect
with smoke tester. Go back to Step 9.
N/A 2006-2007 MX-5 (VIN: JM1NC******111723 125568)
2007 CX-7 (VIN: JM3ER******100057 - 128616)
16 Take action based on the affected model.
Refer to TSB 01-040/09 (MIL ILLUMINATED P0455 SET) and perform the repair, then go to
the next step.
2004-2009 Mazda3
2007-2009 Mazdaspeed3
2006-2009 Mazda5
Page 8 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
If the fuel cap is not a modified (improved) part,
replace it with a modified part according to TSB
01-020/10 (LOOSE FUEL FILLER CAP WITH DTC
P0442, P0455 AND P0456), then go to the next
step.
Models other than above:
Go to the next step.
Perform inspection for leakage from fuel filler cap: Yes Go back to Step 4 and check the fuel filler cap
Connect Mazda Modular Diagnostic System (Mand/or fuel filler neck.
MDS) and perform EVAP test (KOEO).
NOTE: EVAP test (KOEO) will finish in approx. two
(2) minutes if the fuel tank is nearly full. In this
case, perform the EVAP test (KOEO) again.
While performing EVAP test (KOEO), use an
Ultrasonic Leak Detector Kit and check for leakage
from fuel filler cap.
17
Is EVAP leakage found from fuel filler cap?
Check EVAP leak from other than fuel filler cap.
Connect Mazda Modular Diagnostic System (M18
MDS) and perform EVAP test (KOEO).
Is any EVAP leak detected?
No Go to the next step.
Yes Trouble is duplicated. It may be able to detect
with smoke tester. Go back to Step 9.
No Repair complete.
Vacuum Pump Leak Test:
1. Perform leak test between vacuum pump and appropriate generic adapter (A) to be used during the
testing:
a. Connect appropriate generic adapter to vacuum pump and ensure vacuum pressures (b
and c) can be held between locations (D and E).
b. Apply vacuum pressure of 60 kPa {18 inHg} of vacuum and monitor for 20 seconds.
c. Apply vacuum pressure of 10 kPa {3 inHg} of vacuum and monitor for 20 seconds.
Page 9 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
d.
EVAP System Leak Detection Using Smoke Tester:
NOTE: For additional information regarding the following procedure, reference the EVAP system leak
detection owners manual.
2. Calibrate the leak tester for diagnosis.
a. Verify that the control valve on the panel is in the HOLD position, then open the nitrogen bottle
valve.
A - Control Valve
B - Gauge
C - Flow Meter
D - EVAP Tester Hose
b. Connect the vehicle interface hose (part of generic adapter) to the SELF-TEST port located on
the control panel. Hand tighten the fitting (do not over-tighten).
c. 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 above range, adjust the pressure by turning the black knob (A)
on the low pressure regulator on the nitrogen bottle.
Page 10 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
d. After verifying the regulator is properly calibrated, turn the control valve to the HOLD position.
e. Verify the gauge holds pressure and the flow meter reads no flow.
3. Disconnect the vacuum tube at or near the purge control valve on the charcoal canister side (shaded
area below); Insert the appropriate smoke tester adapter into the vacuum tube at location (K).
NOTE: If the smoke tester is input using the fuel filler cap adapter (as shown on MGSS online
instructions or the Workshop Manual), leakage from the fuel filler cap will not be detected.
a. Close the change over valve (COV) using Mode 8.
b. NOTE: M-MDS Mode 8 will release the COV after ten (10) minutes. Close the COV again
as necessary to finish the inspection.
c. Induce smoke into the system.
d. Loosen the fuel cap (J) until the smoke starts coming out. Close the fuel cap and inspect
the EVAP system for leaks.
Page 11 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 01-002/18
Last Issued: 01/30/2018
A - EVAP System Leak Detection Pump G - PCV Valve
B - Air Filter
H - Rollover Valve
C - Charcoal Canister
I - Fuel Shut-Off Valve
D - Purge Solenoid Valve
J - Fuel Filler Cap
E - Check Valve
K - Hook Up SmokeTester (Canister Side)
F - EGR Valve
---
Page 12 of 12
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.