Evap small leak
September-26th-2007, 03:51 PM
#1
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Join Date: Oct 2005
Location: Viginia,Winchester
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Evap small leak
Hey just curious to see if any one else had this CEL coming on. I think it comes out as a 404 or 440. It says evap system small leak. I pretty sure it has something to do with my recently installed CAI. I'm thinking something isn't tight enough somewhere. Anybody ???
September-26th-2007, 05:59 PM
#2
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Join Date: Oct 2005
Location: California
Posts: 175
CAI has nothing to do with it. I had my CEL on 4 times already for no reason. First time I went to the dealer they said I didn't tight the gas cap (complete BS). Second time I think they said he same thing. Third, it was a gross leak so the guy suspected some kind of a pressure pump(?). Fourth, the light came on and stayed on for like 3-4 days and I contacted some attorneys to see if the car is lemon and they said to bring it to the dealer once again. Before I had the chance to get there the light went off so now I'm waiting for it to come on again and I'll be at the dealer same day. If you look it up on google You'll find many people complaining about that and all of them were told they didn't tight the cap. 
September-26th-2007, 06:55 PM
#3
Tech/How-To/Northeast Mod
Join Date: Feb 2006
Location: Rochester, New York
Posts: 2,517
CAI has nothing to do with it. I had my CEL on 4 times already for no reason. First time I went to the dealer they said I didn't tight the gas cap (complete BS). Second time I think they said he same thing. Third, it was a gross leak so the guy suspected some kind of a pressure pump(?). Fourth, the light came on and stayed on for like 3-4 days and I contacted some attorneys to see if the car is lemon and they said to bring it to the dealer once again. Before I had the chance to get there the light went off so now I'm waiting for it to come on again and I'll be at the dealer same day. If you look it up on google You'll find many people complaining about that and all of them were told they didn't tight the cap.
September-26th-2007, 07:12 PM
#4
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Join Date: Mar 2007
Location: Rockland, Maryville
Posts: 837
This happened to my Miata. Once I took it in and the dealer "cleaned" the fuel line for $220 (before I knew anything about cars). More likely they cleared the code and tightened the gas cap.
About 30K miles later the same code came up, while I was selling the car. Dealer recommended buying a new gas cap. BS. Sold it with the CEL blazing.
I admit it wasn't my practice to tighten the gas cap until it clicked several times, as you should (and I think it says on the fuel door
).
I read it's possible to pump smoke containing a UV dye marker into the evap system to locate the leak. Maybe ask the dealer about that.
About 30K miles later the same code came up, while I was selling the car. Dealer recommended buying a new gas cap. BS. Sold it with the CEL blazing.
I admit it wasn't my practice to tighten the gas cap until it clicked several times, as you should (and I think it says on the fuel door
).I read it's possible to pump smoke containing a UV dye marker into the evap system to locate the leak. Maybe ask the dealer about that.
September-28th-2007, 02:24 PM
#8
Tech/How-To/Northeast Mod
Join Date: Feb 2006
Location: Rochester, New York
Posts: 2,517
The air intake is the only non-pressurized part of the whole intake system, so a leak there wouldn't be a boost leak. The evap system is more descriptively called "Evaporative Emissions Control System".. i.e. your gas tank, fuel lines, etc are all fair game, not something like an intake.
It could be your evap purge control solenoid, your evap charcoal canister, the gas cap, or a couple other related things causing that light.
Here's some related TSB information:
Model Starting S/N Ending S/N
2004 MAZDA3 00000000 ZZZZZZZZ
Some vehicles may exhibit a MIL ON condition with DTCs P0442, P0455,
and/or P0456 stored in memory. See the following list for possible
causes.
Capture freeze frame data, then clear all DTCs. Run the WDS evaporative
system test to confirm the leak. If vehicle fails, use the Mazda
approved, EVAP Tester (Model #134-01049) to further diagnose. Activate
Mode 8 to manually close the Change Over Valve (COV). Note that
the purge solenoid valve is Normally Closed. Run the gas leak test and
the smoke test to confirm leak location.
On Mazda3, the following conditions have been found:
o STUCK OPEN PURGE SOLENOID VALVE - Confirm by removing purge
solenoid control valve hose at the intake manifold, then inspect
to see if smoke exits from the hose. If smoke is seen, this
indicates a valve that is stuck open.
Note: If hose is not removed, smoke may not be seen anywhere, and
it will appear the vehicle has no leak.
o MISSING "BASKET" SEAL - A smoke test will reveal if a basket seal
is missing from a quick disconnect fitting.
2004 MAZDA3 00000000 ZZZZZZZZ
Some vehicles may exhibit a MIL ON condition with DTCs P0442, P0455,
and/or P0456 stored in memory. See the following list for possible
causes.
Capture freeze frame data, then clear all DTCs. Run the WDS evaporative
system test to confirm the leak. If vehicle fails, use the Mazda
approved, EVAP Tester (Model #134-01049) to further diagnose. Activate
Mode 8 to manually close the Change Over Valve (COV). Note that
the purge solenoid valve is Normally Closed. Run the gas leak test and
the smoke test to confirm leak location.
On Mazda3, the following conditions have been found:
o STUCK OPEN PURGE SOLENOID VALVE - Confirm by removing purge
solenoid control valve hose at the intake manifold, then inspect
to see if smoke exits from the hose. If smoke is seen, this
indicates a valve that is stuck open.
Note: If hose is not removed, smoke may not be seen anywhere, and
it will appear the vehicle has no leak.
o MISSING "BASKET" SEAL - A smoke test will reveal if a basket seal
is missing from a quick disconnect fitting.
2004 Mazda3 (2.0L & 2.3L, California spec only)
DESCRIPTION
Some vehicles may experience MIL illumination with DTC P0456 stored in PCM memory.
P0456: Evaporative emission control system leak detected (very small leak)
The DTC may be caused by incorrect software calibration in the PCM.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
NOTE: This repair is not intended to fix normal evaporative system leak issues. It is important to perform all diagnostic checks and repair system leaks prior to starting the following procedure.
1. Verify concern.
2. Using WDS B32.9 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.
CAUTION: Make sure correct calibration part number is used based on transmission.
NOTE:
* Always update WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS Calibration" on ESI and download the "update" file. If PTU is not updated to the latest WDS calibration level, the calibration file will not install into the PTU.
* It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the WDS reprogramming procedure.
* WDS shows the calibration part numbers after programming the PCM.
* Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software, and additional revisions made to those calibrations for service related concerns.
* When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.
* When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it will damage the WDS PTU. Also the external battery power supply cable should be connected to the vehicle battery and the PTU.
3. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
NOTE: After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).
4. Place an "Authorized Modification" label (P/N 9999-95-AMDC-97) with the new calibration information near the Emission Control Information Label located on the hood or in the engine compartment.
DESCRIPTION
Some vehicles may experience MIL illumination with DTC P0456 stored in PCM memory.
P0456: Evaporative emission control system leak detected (very small leak)
The DTC may be caused by incorrect software calibration in the PCM.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
NOTE: This repair is not intended to fix normal evaporative system leak issues. It is important to perform all diagnostic checks and repair system leaks prior to starting the following procedure.
1. Verify concern.
2. Using WDS B32.9 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.
CAUTION: Make sure correct calibration part number is used based on transmission.
NOTE:
* Always update WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS Calibration" on ESI and download the "update" file. If PTU is not updated to the latest WDS calibration level, the calibration file will not install into the PTU.
* It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the WDS reprogramming procedure.
* WDS shows the calibration part numbers after programming the PCM.
* Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software, and additional revisions made to those calibrations for service related concerns.
* When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.
* When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it will damage the WDS PTU. Also the external battery power supply cable should be connected to the vehicle battery and the PTU.
3. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
NOTE: After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).
4. Place an "Authorized Modification" label (P/N 9999-95-AMDC-97) with the new calibration information near the Emission Control Information Label located on the hood or in the engine compartment.
http://www.protegefaq.net/tsb/01-045-04.html
http://www.protegefaq.net/tsb/01-001-05.html
there's a bunch of TSBs for it.. some of them supersede others, but as you can see there's a lot that can be going on, from simple things like a broken/leaky check valve to a gas cap to a miscalibrated PCM.
October-6th-2007, 08:15 PM
#9
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Thread Starter
Join Date: Oct 2005
Location: Viginia,Winchester
Posts: 32
Reflash ECU
I was reading on another forum and some cats were talking about a new recall to reflash the ECU, any clue, if so do you think it could have something to do with those EVAP small leak CEL?
October-23rd-2007, 06:01 PM
#10
Registered User
Join Date: Sep 2007
Posts: 1
I had my ECU reflashed back about 6 months ago because of the CEL and the EVAP small leak issue. The steps they took on my car (or at least they said they took) were to reflash the ECU, change the gas cap, and do a smoke test on the evap system. Since they "fixed" the problem, it came back and now I have a small and gross leak detected. I replaced the purge soleniod valve and it didn't fix the problem. Anyone have any ideas on the next step to fix this? Is there a way to do a leak test on your own?
November-9th-2007, 09:55 PM
#11
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Thread Starter
Join Date: Oct 2005
Location: Viginia,Winchester
Posts: 32
update
Yeah I became pretty chum chum with my mazda tech for stupid reasons just like this. Troy the tech repalced the purge silanoid valve. I also told him about the evap cel that keeps coming up, he ran a diagnostic on the car real quick and he then pointed out a part right beside the purge valve he just repalced and told me that the bla bla bla is you're problem. For the life of me I can't remember what he said. Anyway he said that it was a pretty common problem for the Cx7's as well. He placed an order for the part and told me that they would call when it cme in. They actually called me today telling me that they got the part. I'm going Wed. to get it replaced so I'll tell you what "it" is.
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