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Home >> Mazda >> 2002 >> Millenia S >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics - 2.3L >> Diagnostic Tests >> DTC P0455: EVAP Control System, Excessive Leak Or Blockage Detected >> Diagnosis & Repair Procedure
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Diagnosis & Repair Procedure

  1. Ensure FFD has been recorded. See FREEZE FRAME DATA (FFD)  . If FFD has been recorded, go to next step. If FFD has not been recorded, record FFD on repair order, then go to next step.
  2. Verify related repair information is available. Check for related service bulletins and/or on-line repair information availability. If information is available, perform repair or diagnosis according to repair information, if vehicle is not repaired, go to next step. If information is not available, and vehicle is not repaired, go to next step.
  3. Verify related pending code or stored DTCs. Turn ignition off, then on (engine off). Verify related pending code or DTC. See PENDING TROUBLE CODES  . IF DTCs P0443 and/or P1449 are present, go to appropriate DTC inspection. See DIAGNOSTIC TROUBLE CODE DEFINITIONS  . IF DTCs P0443 and/or P1449 are not present, go to next step.
    4. NOTE: When fuel filler caps other than OEM are attached, it is considered a malfunction.
  4. Inspect fuel filler cap. Verify fuel filler cap is not disconnected, loose or damaged. If fuel filler cap is okay, go to next step. If fuel filler cap is not okay, tighten fuel filler cap or replace it if it is damaged, then go to step  28 .
  5. Inspect purge solenoid valve. Perform purge solenoid valve inspection. See PURGE SOLENOID VALVE - AIRFLOW INSPECTION in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If purge solenoid valve is okay, go to next step. If purge solenoid valve is not okay, replace purge solenoid valve, then go to step  28 .
  6. Inspect CDCV. See CANISTER DRAIN CUT VALVE (CDCV) - AIRFLOW INSPECTION in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If CDCV is okay, go to next step. If valve is not okay, replace valve, then go to step  28 .
  7. Classify intermittent or continuous concern. Perform evaporative system test even if it is not a test condition. See EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If system tests are okay, an intermittent concern exists. See INTERMITTENT PROBLEM DIAGNOSIS in TROUBLE SHOOTING - NO CODES article. Inspect purge solenoid valve and CDCV circuit. If system tests are not okay, go to next step.
    8. NOTE: If evaporative emissions tester is not available, go to next step.
  8. Classify evaporative emission control system for leakage or blockage. Carry out evaporative emission control system inspection using evaporative emission tester. See EVAPORATIVE SYSTEM LEAK INSPECTION USING LEAK TESTER in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If Red "FAILED" light turns on(leakage), repair or replace faulty area, then go to step  28 . If Red "FAILED" light does not turn on, go to next step.
  9. Verify repair shop condition. If repair shop is able to perform Drive Mode 4, go to next step. See MODE 4: EVAP SYSTEM REPAIR VERIFICATION  . If repair shop can not perform Drive Mode 4, then go to step  16 .
  10. Monitor EVAP system by Drive Mode 4. Clear DTC from memory using WDS or equivalent scan tool. See CLEARING DIAGNOSTIC TROUBLE CODES  . Run Drive Mode 4 and verify that CDCV and FTP graphs. See MODE 4: EVAP SYSTEM REPAIR VERIFICATION  and FUEL PRESSURE RELEASE in BASIC DIAGNOSTIC PROCEDURES article. If a malfunction is detected. FTP does not change, EVAP monitoring system is inoperative, go to next step. FTP changes, but does not reach 2.0 kPa, there is a large leak in EVAP system, go to step  13 . FTP reaches 2.0 kPa, but suddenly decreases, pressure in fuel tank cannot be reduced and only gas from EVAP line can be drawn. Inspect the following and repair or replace suspected parts:
    • Rollover valve for ventilation resistance.
    • Check valve for inoperative or blockage.
    • air filter for clogging.
    Then go to step  28 . If no leaks were detected in EVAP control system at this time, go to step  32 .
  11. Inspect purge solenoid valve. See PURGE CONTROL SOLENOID in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If purge solenoid valve is okay, go to next step. If purge solenoid valve is not okay, replace purge solenoid valve, then go to step  28 .
  12. Inspect Fuel Tank Pressure (FTP) sensor. Perform FTP sensor inspection. See FUEL TANK PRESSURE SENSOR in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If FTP sensor is okay, go to next step. If FTP sensor is not okay, replace FTP sensor, then go to step  28 .
  13. Inspect catch tank. Remove catch tank and inspect for plugging, damages and pinholes using vacuum pump. If catch tank is okay, go to next step. If catch tank is not okay, replace catch tank, then go to step  28 .
  14. Inspect charcoal canister. Remove charcoal canister and inspect for damage and pinholes. If charcoal canister is okay, go to next step. If charcoal canister is not okay, replace charcoal canister, then go to step  28 .
  15. Inspect CDCV. See CANISTER DRAIN CUT VALVE (CDCV) - AIRFLOW INSPECTION in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If CDCV is okay, inspect EVAP system hoses and repair or replace them if detached, incorrectly installed or cracked, then go to step  28 . If CDCV is not okay, replace CDCV, then go to next step.
  16. Inspect fuel tank pressure sensor. Perform "Inspect Whole EVAP Control System". See SYSTEM LEAK INSPECTION - USING VACUUM PUMP in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. Run whole system check. If WDS or equivalent scan tool value remains at specified readings for a minimum of 2 minutes, no leaks were detected in EVAP control system at this time, go to step  28 . If WDS or equivalent scan tool value does not remain at specified readings for a minimum of 2 minutes, go to next step.
  17. Inspect fuel tank pressure sensor. See FUEL TANK PRESSURE SENSOR in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If fuel tank pressure sensor is okay, go to next step. If fuel tank pressure sensor is not okay, replace fuel tank pressure sensor, then go to step  28 .
  18. Inspect leakage from charcoal canister to fuel tank. See SYSTEM LEAK INSPECTION - USING VACUUM PUMP in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If WDS or equivalent scan tool value remain at specified readings for a minimum of 2 minutes, go to step  23 . If WDS or equivalent scan tool value does not remain at specified readings for a minimum of 2 minutes, go to next step.
  19. Inspect attached accessories on fuel tank. Remove fuel tank and inspect for damage, insufficient sealing or poorly installed accessories on fuel tank, such as fuel gauge. If all items are okay, go to next step. If all items are not okay, repair or replace fuel tank and/or accessories, then go to step  28 .
  20. Inspect fuel shut-off valve for ventilation. See FUEL SHUT-OFF VALVE (MILLENIA) in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If fuel shut-off valve is okay, go to next step. If fuel shut-off valve is not okay, replace fuel tank, then go to step  28 .
  21. Inspect rollover valve for ventilation. If rollover valve is okay, go to next step. If rollover valve is not okay, replace fuel tank, then go to step  28 .
  22. Inspect vent pressure control valve. Remove pressure control valve and inspect. If pressure control valve is okay, inspect the following hoses and repair or replace if detached, incorrectly installed or cracked:
    • Charcoal canister to pressure control valve.
    • Pressure control valve to fuel tank.
    • Fuel filler pipe to pressure control valve.
    • Fuel tank pressure sensor to pressure control valve.
    Then go to step  28 . If pressure control valve is not okay, replace filler pipe component, then go to step  28 .
  23. Inspect leakage from charcoal canister to purge solenoid valve. See SYSTEM LEAK INSPECTION - USING VACUUM PUMP in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If vacuum remains at specified readings for a minimum of 2 minutes, go to step  28 . If vacuum does not remain at specified readings for a minimum of 2 minutes, go to next step.
  24. Inspect catch tank. Remove catch tank and inspect for plugging, damages and pinhole using vacuum pump. If catch tank is okay, go to next step. If catch tank is not okay, replace catch tank, then go to step  28 .
  25. Inspect purge solenoid valve. Remove purge solenoid valve and inspect for damage and air leakage. If purge solenoid valve is okay, go to next step. If purge solenoid valve is not okay, replace purge solenoid valve, then go to step  28 .
  26. Inspect charcoal canister. Remove charcoal canister and inspect for plugging, damage and pinholes. If charcoal canister is okay, go to next step. If charcoal canister is not okay, replace charcoal canister, then go to step  28 .
  27. Inspect Canister Drain Cut Valve (CDCV). See CANISTER DRAIN CUT VALVE (CDCV) - AIRFLOW INSPECTION in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If CDCV is okay, inspect hoses from charcoal canister to CDCV and repair or replace if detached, incorrectly installed or cracked, then go to next step. If CDCV is not okay, replace CDCV, then go to next step.
  28. Decide on after repair procedure according to repair shop condition. Clear DTC from PCM memory using WDS or equivalent scan tool. See CLEARING DIAGNOSTIC TROUBLE CODES  . If repair shop is able to perform Drive Mode 4, see MODE 4: EVAP SYSTEM REPAIR VERIFICATION  , go to step  31 . If repair shop is unable to perform Drive Mode 4, go to next step.
    29. NOTE: If DTC appears, ignore DTC.
  29. Verify EVAP system repaired. Carry out evaporative system test even if it is not a test condition. See SYSTEM LEAK INSPECTION - USING VACUUM PUMP in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If system test result is okay, EVAP system is repaired. If system test result is not okay, go to next step.
  30. Verify EVAP system repaired by evaporative system test. Carry out evaporative system test even if it is not a test condition. See SYSTEM LEAK INSPECTION - USING VACUUM PUMP in SYSTEM & COMPONENT TESTING - MIATA, MILLENIA, MPV, PROTEGE, PROTEGE5 & 626 article. If system test result is okay, EVAP system is repaired, go to step  33 . If system test result is not okay, replace PCM, then go to step  33 .
  31. Monitor EVAP system by Drive Mode 4. See MODE 4: EVAP SYSTEM REPAIR VERIFICATION  . Stop vehicle and access on-board system readiness test menu to inspect drive mode completion status. See ON-BOARD SYSTEM READINESS TEST  . If evaporative purge system has been monitored, go to next step. If evaporative purge system has not been monitored, retry this step.
  32. Verify EVAP system repaired. Access diagnostic monitoring test results. Verify test ID 10:22:00 value. See DIAGNOSTIC MONITORING TEST RESULTS  . If it is below maximum value, go to next step. If it is not below maximum value, replace PCM, then go to next step.
  33. Perform after repair procedure. See AFTER REPAIR PROCEDURE  . If there are any DTCs present, go to applicable DTC inspection. See DIAGNOSTIC TROUBLE CODE DEFINITIONS  . If there are no DTCs present, trouble shooting is complete.
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