Emission System (Lf, L3): Removal & Installation Mazda 3 BL

EVAP System Leak Detection Pump Removal Note

1. Support the rear crossmember using a transmission jack.
2. Remove the rear wheels.
3. Disconnect the ABS wheel-speed sensor wiring harness connector.
4. Disengage the brake pipe mount from bracket.
5. Remove the rear shock absorber lower bolts. (See «REAR SHOCK ABSORBER REMOVAL/INSTALLATION»(ref-345299-S21659066612009102000000) .)
6. Loosen the rear crossmember installation nuts (6 locations) and lower the rear crossmember approx. 140 mm {5.5 in}. (See «REAR CROSSMEMBER REMOVAL/INSTALLATION»(ref-345299-S12346880182009102000000) .)
7. Disconnect the breather hose.
8. Remove the installation bolt and remove the EVAP system leak detection pump.

Scheme 28

1. Install the breather hose and clamp as shown in the figure.

Water Hose Removal Note

1. Drain the engine coolant from the radiator. (See «ENGINE COOLANT REPLACEMENT [LF, L3]»(ref-345218-S35273147202009102000000) .)

EGR Valve Removal Note

1. Remove the air cleaner and air hose. (See «INTAKE AIR SYSTEM REMOVAL/INSTALLATION [LF, L3]»(ref-345212-S03134740962009102000000) .)
2. Remove the radiator hose (upper). (See «RADIATOR REMOVAL/INSTALLATION [LF, L3]»(ref-345218-S29634696342009102000000) .)

Retainer Removal Note

Scheme 29

1. Insert a flat blade screwdriver with its tip wrapped in a waste cloth into the gap between the retainer and the oil separator as shown in the figure.
2. Spread the side surface of the retainer outward to dismount it with attention to the tab.

Retainer Installation Note

1. Make sure that the retainer alignment mark is directed as shown in the left diagram before installing the retainer to the oil separator.

Scheme 30

1. Remove the intake manifold.
2. Remove the PCV valve.
3. Verify that there is no airflow when pressure is applied to port A. If there is airflow, replace the PCV valve.
4. Verify that there is airflow when vacuum is applied to port A. If there is no airflow, replace the PCV valve.

ROLLOVER VALVE REMOVAL/INSTALLATION [LF, L3]

Note. Except for the California emission regulation applicable model, the rollover valve cannot be removed as it is welded on the upper surface of the fuel tank. For the California emission regulation applicable model, the rollover valve cannot be removed as it is built into the fuel tank.

FUEL SHUT-OFF VALVE REMOVAL/INSTALLATION [LF, L3]

Note. Except for the California emission regulation applicable model, the fuel shut-off valve cannot be removed as it is welded on the upper surface of the fuel tank. For the California emission regulation applicable model, the fuel shut-off valve cannot be removed as it is built into the fuel tank.

Type A Removal

Note. The evaporative hose can be removed by pushing it to the joint port side to release the lock.

Scheme 31

Scheme 32

1. Rotate the release tab on the quick release connector to the stopper position.
2. Pull out the evaporative hose straight from the joint port and disconnect it.
3. Cover the disconnected quick release connector and joint port with vinyl sheeting or a similar material to prevent it from scratches or dirt.

Type B Removal

Note. When a prompt connector is detached, following SST can be used. 49N013103A 49E042 001

Scheme 33

1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before performing any work operations. (See «BEFORE SERVICE PRECAUTION [LF, L3]»(ref-345209-S03614746822009102000000) .)
2. Verify that the quick release connector joint area is free of foreign material. Clean if necessary.
3. Install the SST as shown in the figure and push into the quick release connector to disconnect the fuel pipe.
4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.

Type A Installation

Note. If the quick release connector O-ring is damaged or has slipped, replace the evaporative hose. A checker tab is integrated with the quick release connector for new evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the joint port.

Scheme 34

1. Inspect the evaporative hose and joint port sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
2. Apply a small amount of clean engine oil to the sealing surface of the joint port.
3. Reconnect the evaporative hose straight to the joint port until a click is heard. NOTE: If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0-3.0 mm {0.08-0.12 in} and is connected securely.

Type B Installation

Note. Use only the designated genuine retainer when replacing the retainer.

Scheme 35

1. Verify that the sealing surfaces of the fuel hose or fuel pipe have no damage or deformation. Replace if necessary. If the O-ring of the quick release connector is damaged or displaced, replace the fuel hose.
2. Install a new retainer to the quick release connector, then visually verify that the retainer tab is installed securely to the connector.
3. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
4. Push the quick release connector into the fuel pipe until a click is heard.
5. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0-3.0 mm {0.08-0.12 in} and is connected securely. If the quick release connector does not move at all, verify that the O-ring is not damaged or has slipped, and then reconnect the connector.
6. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See «AFTER SERVICE PRECAUTION [LF, L3]»(ref-345209-S30260717232009102000000) .)

Type C Installation

Note. If the quick release connector O-ring is damaged or has slipped, replace the evaporative hose.

1. Inspect the evaporative hose and joint port sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
2. When disconnecting and reconnecting the quick release connector, verify if the metal reinforcement pipe protrudes from the plastic pipe end while pressing the end with a finger. If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe.
3. Insert the joint port straight to the end of the quick release connector.
4. Push down the retainer using a finger. If the retainer cannot be pushed down, push the joint port further to the quick release connector.
5. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

Type D Installation

Note. If the quick release connector O-ring is damaged or has slipped, replace the evaporative hose.

1. Inspect the evaporative hose and joint port sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
2. Apply a small amount of clean engine oil to the sealing surface of the joint port.
3. Reconnect the evaporative hose straight to the joint port until a click is heard. NOTE: If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

Type E Installation

Note. If the quick release connector O-ring is damaged or has slipped, replace the evaporative hose.

1. Inspect the evaporative hose and joint port sealing surface for damage and deformation. If there is any malfunction, replace it with a new one.
2. Apply a small amount of clean engine oil to the sealing surface of the joint port.
3. Reconnect the evaporative hose straight to the joint port until a click is heard. NOTE: If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.