TSB: 01-003/06

2004-2005 MAZDA3 - MIL ILLUMINATION - P0456

NOTE: This bulletin replaces 01-039/04. Please update your records accordingly.

BULLETIN NOTE

This bulletin supersedes the previous bulletin 01-039/04, issued on 10/20/2004. The REPAIR PROCEDURE and CALIBRATION INFORMATION have been revised.

APPLICABLE MODEL(S)/VINS

2004-2005 Mazda3 (2.0L & 2.3L, California spec only)

DESCRIPTION

Some vehicles may experience MIL illumination with DTC P0456 stored in PCM memory. The DTC may be caused by incorrect software calibration in the PCM.

• P0456: Evaporative emission control system leak detected (very small leak)

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. Reboot the WDS PTU to clear memory before reprogramming.

3. Using WDS B40.8 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.

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. Also the external battery power supply cable should be connected to the vehicle battery and the PTU.

4. 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:

• If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.

• After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).

5. Fill out an "Authorized Modifications" label (P/N 9999-95-AMDC-97) with the new PCM calibration information, your dealer code, and today's date.

6. Place the "Authorized Modifications" label on the "A" pillar below 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.

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.