TSB: 01-025/05

2004-2006 MAZDA3, MAZDA6 - MIL ILLUMINATION, P0171 / P0172 / P0441 / P0442 / P0455 / P0456 / P2177 / P2178 / P2187 / P2188

BULLETIN NOTE

This bulletin supersedes the previous bulletin 01-045/04, issued on 12/21/04. The APPILCABLE MODEL(S), PART(S) and WARRANTY INFORMATION have been revised.

APPLICABLE MODEL(S)/VINS

2004 - 2006 MAZDA3

2004 - 2006 MAZDA6 2.3L

DESCRIPTION

Some vehicles may experience MIL illumination with DTC P0171 / P0172 / P0441 / P0442 / P0455 / P0456 /P2177 / P2178 / P2187 / P2188 stored in PCM memory.

P0171: Fuel trim system too lean. (Federal Spec.)

P0172: Fuel trim system too rich. (Federal Spec.)

P0441: Evaporative emission control system incorrect purge flow.

P0442: Evaporative emission control system leak detected (small leak)

P0455: Evaporative emission control system leak detected (gross leak)

P0456: Evaporative emission control system leak detected (very small leak) (Calif. Spec.)

P2177: Fuel system too lean at off idle. (Calif. Spec.)

P2178: Fuel system too rich at off idle. (Calif. Spec.)

P2187: Fuel system too lean at idle. (Calif. Spec.)

P2188: Fuel system too rich at idle. (Calif. Spec.)

This may be due to a stuck opened purge solenoid valve.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify concern.

2. Capture freeze frame data then clear all DTCs.

3. Inspect the airflow sealing of the purge solenoid valve by using the Purge Solenoid Test Cap (MT04-F2-001) and vacuum pump below. Apply vacuum to at least 20”. The vacuum reading should hold indefinitely.

• If the vacuum reading does not hold, replace the purge solenoid valve.

• If the vacuum reading holds, go to next step.

NOTE: Make sure the Purge Solenoid Test Cap (MT04-F2-001) does not leak at the fitting before testing purge solenoid valve.

4. Cycle purge solenoid valve a few times to check for intermittent sealing issues. Refer to page 01-16-14 Airflow Inspection of 2004 Mazda3 Workshop Manual and page 01-16-15 Airflow Inspection of 2004 Mazda3 Workshop Manual.

TOOL(S) INFORMATION

PART(S) INFORMATION

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information.

• Additional diagnostic time cannot be claimed for this repair.