Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMAZDA20086 S SPORT, 4D HATCHBACK, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 25 (ENGINE CONTROLS - SYSTEM & COMPONENT TESTING)EMISSION SYSTEMS & SUB-SYSTEMSFUEL EVAPORATIVE SYSTEM (EXCEPT MPV)FUEL-FILLER CAP INSPECTION
2008 Mazda 6 s Sport, 4D Hatchback, Standard
Fuel-Filler Cap Inspection
2008 Mazda 6 s Sport, 4D Hatchback, StandardSECTION Fuel-Filler Cap Inspection
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2002 Mazda Protege5, 2002 Mazda Protege, 2002 Mazda Millenia, 2002 Mazda MX-5 Miata, and 2002 Mazda MPV. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Perform this test using Mazda Special Service Tool (SST) - Evaporative Emission System Tester (MZ254AT3641).
Evaporative Emission System Tester Self Test
- Verify gas cylinder valve is closed and control valve (located on tester) is in TEST position. All tester displays should be off at this time.
- Connect long hose (part of SST ) to tester.
- Connect manifold assembly (part of SST ) to long hose as shown.
- Open gas cylinder valve and verify gas cylinder regulator left gauge reads 10 to 12 psi (preset at factory). If not, see tester operators manual to contact tester manufacturer.
- Press ON/OFF switch to turn on SST and make sure left display reads 0.0. Turn control valve on tester to FILL position.
- Verify left display reading is within 13.9 to 14.0 inches of water. If not, adjust pressure using regulator knob located on right side of tester.
- Turn control valve to TEST position and press START switch.
- After 2-minute countdown (left display) is completed, right display shows total pressure loss for that period. A 0.5 inch of water loss is acceptable on self-test. If loss is more than 0.5 inch of water, perform one or more self-test. If failed test repeats, check for leak using the ultrasonic leak detector (part of SST ).
Leakage Inspection
- Press RESET switch to set left display reading to 0.0.
- Connect fuel cap receiver assembly (part of SST ) to manifold assembly and fuel-filler cap from vehicle. If fuel-filler cap is not a Mazda part, replace it.
- Turn control valve to FILL position.
- Wait (maximum 20 seconds) until left display reads 13.9-14 inches of water. If reading is slightly below, adjust it using regulator knob. If reading is far below, fuel-filler cap has leak. Replace fuel-filler cap.
- Turn valve to EST position and press START switch.
- After 2-minute countdown (left display) is completed, check test result (FAILED/PASSED light on tester). If Green light turns on, fuel-filler cap is OK. If the Red light turns on, fuel-filler cap has leakage. Replace fuel-filler cap.
- Close gas cylinder valve.
- Turn control valve to FILL position.
- Press ON/OFF switch to turn off tester.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.