TSB: 01-040/06

2004 MAZDA3 - MIL ILLUMINATION WITH DTC P0442 / P0455 / P0456

NOTE: This bulletin replaces 01-001/05. Please update your records accordingly.

BULLETIN NOTE

This bulletin supersedes the previous bulletin 01-001/05, issued on 01/07/05. The REPAIR PROCEDURE has changed.

APPLICABLE MODEL(S)/VINS

2004 MAZDA3 with VINs lower than JM1BK**** ** 217953

DESCRIPTION

Some vehicles may experience MIL illumination with DTC P0442/P0455/P0456 stored in PCM memory.

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 – California emissions regulation only)

This may be due to fuel cap swell. The fuel cap has been modified to correct this concern.

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

REPAIR PROCEDURE

NOTE: This repair is not intended to fix evaporative system leak issues other than the fuel cap. In addition to checking the fuel cap, it is important to perform all diagnostic checks and repair system leaks.

1. Verify concern.

2. Capture freeze frame data then clear all DTCs.

3. Compare fuel cap to illustration below. If "old" style fuel cap, replace with P/N BN8F-42-250B.

4. Run the IDS/PDS EVAP system test to verify repair.

NOTE: It is possible to cross thread the fuel cap when tightening it. If this happens, evaporated fuel may leak and the MIL may turn on again. Please explain to the customer to fit the fuel cap carefully before tightening it.

PART(S) INFORMATION

WARRANTY INFORMATION

NOTE:

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

• Additional diagnostic time cannot be claimed for this repair.