Emission System: Removal & Installation Mazda RX-8 I

Evaporative Chamber Installation Note

1. Install the evaporative chamber to the hose.
2. Insert the evaporative chamber into crossmember No. 5.

EVAP System Leak Detection Pump Installation Note

1. Install the bracket on the EVAP system leak detection pump.
2. Install the connector A.
3. Install the connector B.
4. Install the clip.

Scheme 10

1. Warm up the engine and idle it.
2. Turn the ignition switch off.
3. Disconnect the quick release connector going to the charcoal canister from the engine room side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
4. Start the engine and idle it.
5. After warming up the engine, verify that the vacuum is not present by placing a finger on the quick release connector for approx. 30 s as shown in the figure. If the vacuum is not present, inspect the following: PCM terminal voltage Evaporative purge control Purge solenoid valve
6. Verify that the vacuum is not present after approx. 30 s from the engine starting. If the vacuum is not present, inspect the following. PCM terminal voltage Intake air temperature Evaporative purge control Throttle opening angle Load/No load identifying signal Purge solenoid valve

Scheme 11

Scheme 12

1. Warm up the engine and idle it.
2. Turn the ignition switch off.
3. Disconnect the quick release connector going to the charcoal canister from the engine room side. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION»(ref-178411-S01806597482005061500000) .)
4. Start the engine and idle it.
5. After warming up the engine, verify that the negative pressure is not operating by placing a finger on the quick release connector for approx. 30 s as shown in the figure. If the vacuum is not present, inspect the following: PCM terminal voltage Evaporative purge control Purge solenoid valve
6. Connect the quick release connector. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION»(ref-178411-S01806597482005061500000) .)
7. Connect the WDS or equivalent to the DLC-2.
8. When operating the purge solenoid valve of DUTY 0% at DUTY 100% using simulation function EVAPCP, verify that the engine idles roughly or stops. If the idling condition does not change, inspect the following. Turn the ignition switch to the ON position. When operating the purge solenoid valve of DUTY 0 % at DUTY 50 % using simulation function EVAPCP, verify that purge solenoid valve can be heard operating. If there is no sound of operation, inspect the following. Vacuum hose: disconnection, damage (extension manifold (upper)-purge solenoid valve-charcoal canister) Wiring harnesses, connectors: open circuit (main relay D terminal-purge solenoid valve-PCM 2P terminal) If there is no sound of operation, inspect the following. Purge solenoid valve

Scheme 13

1. Disconnect the negative battery cable.
2. Remove the extension manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000) .)
3. Remove the purge solenoid valve.
4. Inspect air flow between the ports under the following conditions

Scheme 14

1. If there is air flow, inspect the related wiring harnesses.
2. If there is no air flow, replace the purge solenoid valve.

Scheme 15

1. Remove the extension manifold (upper). (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000) .)
2. Seal the catch tank on the purge solenoid valve side.
3. Inspect for air leakage when blowing air using your mouth from the charcoal canister side. If air leaks, replace the extension manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000) .)

Scheme 16

1. Remove the air filter. (See «EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM REMOVAL/INSTALLATION»(ref-178415-S20195069272005061500000) .)
2. Blow from port A and verify that there is airflow from port B. If not as specified, replace the air filter.
3. Blow from port B and verify that there is airflow from port A. If not as specified, replace the air filter.

Scheme 17

Scheme 18

1. Remove in the order indicated. (Scheme 17)
2. Install in the reverse order of removal.

Scheme 19

Scheme 20

1. Remove the secondary air injection control valve. (See «SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION»(ref-178415-S40450229912005061500000) .)
2. Verify that there is no air flow between A and B of the AIR control valve port. If there is air flow, replace the AIR control valve. (See «SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION»(ref-178415-S40450229912005061500000) .)
3. Install the vacuum pump to the AIR control valve.
4. Pressurize the actuator valve of the AIR control with a negative pressure of approx. 60 kPa {0.61 kgf/cm 2 , 8.7 psi}. CAUTION: Since the valve actuator of the AIR control could be damaged, do not pressurize positive pressure or negative pressure more than 100 kPa {1.02 kgf/cm 2 , 14.5 psi}.
5. Blow air through port A, then verify that there is air flow. If there is no air flow, replace the AIR control valve.
6. Blow air from through port B, then verify that there is no air flow. If there is air flow, replace the AIR control valve. (See «SECONDARY AIR INJECTION (AIR) CONTROL VALVE REMOVAL/INSTALLATION»(ref-178415-S40450229912005061500000) .)

Scheme 21

Scheme 22

1. Remove the extension manifold (upper). (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).)
2. Remove in the order indicated. (Scheme 21)
3. Install in the reverse order of removal.

Scheme 23

Scheme 24

Scheme 25

1. Connect the WDS or equivalent to the DLC-2.
2. Warm up the engine to normal operating temperature.
3. Verify that AIR pump is not operating when idling. If the AIR pump is operating, inspect the following items and repair or replace the malfunctioning location. AIR pump relay stuck closed Short circuit of the wiring harness to ground system (PCM terminal 40-AIR pump relay terminal A)
4. When AIP RLY is turned from off to on, verify that the AIR pump relay and secondary injection pump can be heard operating. If there is no sound of operation from the AIR pump relay, inspect the following items and repair or replace the malfunction part. AIR pump relay stuck open Wiring harness, connectors: open circuit (PCM terminal 40-AIR pump) Wiring harness, connector: open circuit (main relay terminal D-AIR pump relay terminal A) If there is no sound of operation from the AIR pump, inspect the following items and repair or replace the malfunction part. Wiring harness, connectors: open or short circuit (Battery-AIR pump relay-AIR pump terminal A) Wiring harness, connectors: open or short circuit (AIR pump terminal B-ground)
5. Inspect the discharging pressure of the AIR pump. (See «Discharging Pressure Inspection»(ref-178415-S06609191452005061500000) .) If the discharging pressure is not as specified, replace the AIR pump.
6. Remove the vacuum hose connected to the AIR control valve.
7. Verify that vacuum hose removed when idling is not pressurized with negative pressure. If the negative pressure can be verified, perform the following inspections and repair or replace the malfunction part. AIR solenoid valve stuck open Wiring harness, connectors to ground: short circuit (PCM terminal 1O-AIR solenoid valve terminal B)
8. Verify that there is negative pressure when the AIR solenoid valve is turned on from off using the simulation function PACTNV. If the negative pressure cannot be verified, perform the following inspections and repair or replace the malfunction part. AIR solenoid valve stuck closed Wiring harness, connectors: open circuit (PCM terminal 1O-AIR solenoid valve terminal B) Vacuum hose between intake manifold, vacuum tank, AIR solenoid valve, and AIR control valve (clog, leakage, damage, poor connection)
9. Monitor the following PIDs using the monitor function. Heated oxygen sensor (front) (WDS PID: O2S11) AIR pump relay (WDS PID: AIP_RLY)
10. Warm up the engine.
11. Connect the vacuum pump to the AIR control valve.
12. Operate the AIR pump using the simulation function AIP_RLY. CAUTION: Do not operate the AIR pump for more than 1 Min to avoid damaging the pump. Allow 1 hour after air pump has energized for the AIR pump to operating it again. Inspect the following immediately to prevent the catalyst from becoming overheated.
13. Verify that the PID O2S11 shows a lean value when pressurizing the AIR pump using a vacuum pump while idling. If a lean value for the PID O2S11 cannot be confirmed, inspect the following items and repair or replace the applicable part. AIR control valve operation malfunction. (See «SECONDARY AIR INJECTION (AIR) CONTROL VALVE INSPECTION»(ref-178415-S10934017362005061500000) .) Channel between AIR pump and exhaust manifold (clog, leakage)

Scheme 26

Scheme 27

1. Disconnect the negative battery cable.
2. Remove the AIR solenoid valve. (See «SECONDARY AIR INJECTION (AIR) SOLENOID VALVE REMOVAL/INSTALLATION»(ref-178415-S09307407642005061500000) .)
3. Inspect air flow between the ports under the following conditions: If there is no malfunction, inspect the related wiring harnesses. If there is any malfunction, replace the AIR solenoid valve. (See «SECONDARY AIR INJECTION (AIR) SOLENOID VALVE REMOVAL/INSTALLATION»(ref-178415-S09307407642005061500000) .)

Scheme 28

Scheme 29

1. Remove in the order indicated. (Scheme 28)
2. Install in the reverse order of removal.

Scheme 30

Scheme 31

1. Remove the air hose between the AIR pump and AIR control valve at the AIR control valve side.
2. Install the SST on the AIR control side using tape to prevent air leakage.
3. Start the engine, turn all electrical loads off, and idle the engine after completely warning it up.
4. Connect the AIR pump relay terminal A to the ground, and operate the AIR pump. CAUTION: When connecting the secondary air injection pump relay to the body ground, short the specified terminal, because shorting the wrong terminal may cause malfunctions. Do not operate the secondary air injection pump for more than 1 min to avoid damaging the pump. Stop the engine and wait for 1 hour or more after energizing the secondary air injection pump to allow it to cool down before operating it again.
5. Verify that the discharging pressure of the AIR pump is within the specification. If not within the specification of the discharge pressure, inspect the following: PCM terminal 40 voltage AIR pump relay If it is within the specification, inspect continuity for the AIR pump. Discharging pressure 13.7 kPa {0.14 kgf/cm 2 , 1.99 psi} or more

Scheme 32

Scheme 33

1. Remove the air hose between the AIR pump and AIR control valve at the AIR control valve side.
2. Install the SST on the AIR control side using tape to prevent air leakage.
3. Start the engine, turn all electrical loads off, and idle the engine after completely warming it up.
4. Connect the WDS or equivalent to the DLC-2.
5. Turn the PID AIP RLY from off to on position using the simulation function. CAUTION: When connecting the secondary air injection pump relay to the body ground, short the specified terminal, because shorting the wrong terminal may cause malfunctions. Do not operate the secondary air injection pump for more than 1 min to avoid damaging the pump. Stop the engine and wait for 1 hour or more after energizing the secondary air injection pump to allow it to cool down before operating it again.
6. Verify that the discharging pressure of the AIR pump is within the specification. If not within the specification, inspect the following: PCM terminal 40 voltage AIR pump relay If it is within the specification, inspect the continuity for the AIR pump. Discharging pressure 13.7 kPa {0.14 kgf/cm 2 , 1.99 psi} or more

Scheme 34

1. Disconnect the negative battery cable.
2. Disconnect the AIR pump connector.
3. Inspect for continuity between the AIR pump terminals A and B. If there is continuity, inspect the related wiring harnesses. If there is no continuity, replace the AIR pump. (See «SECONDARY AIR INJECTION (AIR) PUMP REMOVAL/INSTALLATION»(ref-178415-S09881387372005061500000) .)

Scheme 35

1. Remove the charcoal canister. (See «EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM REMOVAL/INSTALLATION»(ref-178415-S20195069272005061500000) .)
2. Plug ports A and C, then blow air into port B. CAUTION: Do not apply the pressure more than 20 kPa {0.2 kgf/cm 2 , 2.8 psi} to the charcoal canister. Doing so will damage the charcoal canister.
3. Verify that there is no air leakage from the case. If not as specified, replace the charcoal canister.

Scheme 36

1. Remove the rear differential. (See «REAR DIFFERENTIAL REMOVAL/INSTALLATION»(ref-178165-S10298188272005061200000) .)
2. Remove the evaporative chamber installed on outside air side of the charcoal canister hose.
3. Blow air from port A using your mouth and verify that there is air flow. If there is no air flow, replace the evaporative chamber.
4. Verify that there is no deformation or cracking of the evaporative chamber. If the exterior is not normal, replace the evaporative chamber.