Engine Controls/Emissions - MIL ON/DTC's P2404/P0456
Engine01-033/04
2003-2004 MAZDA6 - MIL ILLUMINATION WITH
DTCs P2404 AND/OR P0456
APPLICABLE MODEL(S)/VINS
2003 - 2004 Mazda6
DESCRIPTION
Some vehicles may exhibit a MIL illumination with DTCs P2402 and/or P0456 stored in memory.
1.
^ P2404 - EVAP System leak detection pump circuit malfunction
The evaporative monitoring system is in operation just after the vehicle is stopped and the ignition key is turned off. If there is an electrical load fluctuation (i.e. keyless entry system) during this time, current flowing to the pump raises quickly. The PCM misdiagnoses this situation as a clogged drain system, causing the MIL to illuminate.
^ P0456 - Evaporative emission control system leak detection (very small leak)
The correction for battery voltage and DMTL (Diagnostic Module Tank Leakage) operation, and the threshold for MIL illumination are incorrect.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify and record present DTC(s).
2. Using WDS, perform the On-Board Evaporative Leak Test procedure.
^ If the system passes the On-Board Evaporative Test, and no fault codes are present, proceed to Step 4.
^ If the system fails the On-Board Evaporative Test, refer to the Workshop Manual to further diagnose the source of the leak, then proceed to Step 3.
3. After the vehicle is repaired, verify the system passes the On-Board Evaporative Test and no DTCs are present. Proceed to Step 4.
4. Using WDS B32.2 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.
NOTE:
^ 2003 Mazda6 2.3L: When reprogramming the PCM to correct the P2404 and P0456 codes, the reprogramming procedure will update the PCM to a 2004 model year level DTC list. See "MAZDA6 2.3L DTC REFERENCE INFORMATION" table in this service bulletin.
^ 2003 Mazda6 3.0L: DTC list will remain the same after reprogramming is completed to correct P2404 and P0456 codes.
NOTE:
^ Always update the 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 the 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.
5. 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).
6. Place an "Authorized Modification" label (P/N 9999-95-AMDC-97) with the new calibration information on the "A" pillar above the tear tag in the driver door jamb.
CALIBRATION INFORMATION
NOTE:
The PCM Calibration Part Numbers listed above are provided for PCM reprogramming purposes only. These are not necessarily the same Mazda part numbers used to order an actual PCM through the Mazda Parts System. It is not necessary to order a PCM as part of this repair procedure.
MAZDA6 2.3L DTC REFERENCE INFORMATION
NOTE:
^ When reprogramming a 2003 Mazda6 2.3L PCM to correct the P2404 and P0456 codes, the reprogramming procedure WILL update the PCM to the 2004 model DTCs listed in the table above.
^ When reprogramming a 2003 Mazda6 3.0L PCM to correct the P2404 and P0456 codes, the reprogramming procedure WILL NOT update the PCM to the 2004 model DTC level.
WARRANTY INFORMATION
^ 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.