DAEWOO MATIZ 2003 Service Repair Manual

ENGINE CONTROLS 1F–53
DAEWOO M-150 BL2
Data Link Connector Diagnosis
StepActionValue(s)YesNo
1
Perform an Euro On-Board Diagnostic (EOBD)
System Check.
Was the check performed?
–
Go to Step 2
Go to “Euro
On-Board
Diagnostic
System Check.
2
With a test light connected to the ground, probe the
Data Link Connector (DLC) battery feed terminal 16.
Is the test light on?
–
Go to Step 4Go to Step 3
3
Repair an open or short to ground in the DLC battery
feed circuit .
Is the repair complete?
–
Go to Step 4
–
4
With a test light connected to the battery, probe the
Data Link Connector (DLC) ground terminal 4 and 5.
Is the test light on?
–
Go to Step 6Go to Step 5
5Repair an open circuit .
Is the repair complete?–Go to Step 6–
6
1. Turn the ignition OFF.
2. Connect a scan tool to the Data Link Connector
(DLC).
3. Turn the ignition ON.
Does the scan tool power up?
–
Go to Step 8Go to Step 7
7
Check for damages in the terminal of DLC and scan
tool, and repair as needed.
Is the repair complete?
–
Go to Step 8
–
8
Using a scan tool, request engine data of Engine
Control Module (ECM).
Does the scan tool display any data?
–
Go to Step 12Go to Step 9
9
Install the scan tool on another vehicle and check for
proper operation.
Does the scan tool work properly on a different
vehicle.
–
Go to Step 11Go to Step 10
10
The scan tool is malfunctioning.
Refer to the scan tool’s manual for repair.
Is the repair complete?
–
Go to Step 12
–
11
Repair communication circuit between ECM and
DLC.
Is the repair complete?
–
Go to Step 12
–
12
1. Using a scan tool, clear the Diagnostic Trouble
Codes(DTCs).
2. Attempt to start the engine.
Does the engine and continue to run?
–
Go to Step 13Go to Step 1
13
1. Allow the engine to idle until normal operation
temperature reached.
2. Check if any DTCs are set?
Are any DTCs displayed that have not been
diagnosed?
–
Go to applicable
DTC table
System OK

1F–54 ENGINE CONTROLS
DAEWOO M-150 BL2
FUEL INJECTOR BALANCE TEST
A fuel injector tester is used to energize the injector for a
precise amount of time, thus spraying a measured
amount of fuel into the intake manifold. This causes adrop in the fuel rail pressure that can be recorded and
used to compare each of the fuel injectors. All of the fuel
injectors should have the same pressure drop.
Fuel Injector Balance Test Example
Cylinder123
First Reading380 kPa
(55 psi)380 kPa
(55 psi)380 kPa
(55 psi)
Second Reading215 kPa
(31 psi)201 kPa
(29 psi)230 kPa
(33 psi)
Amount Of Drop165 kPa
(24 psi)179 kPa
(26 psi)151 kPa
(22 psi)
Average Range: 156-176 kPa
(22.5-25.5 psi)Injector OKFaulty Injector –
Too Much
Pressure DropFaulty Injector –
Too Little
Pressure Drop
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
Caution: Do not pinch or restrict fuel lines. Damage
to the lines could cause a fuel leak, resulting in pos-
sible fire or personal injury.
Notice: In order to prevent flooding of the engine, do not
perform the Injector Balance Test more than once (in-
cluding any retest on faulty fuel injectors) without run-
ning the engine.
Test
Notice: An engine cool down period of 10 minutes is
necessary in order to avoid irregular readings due to hot
soak fuel boiling.
1. Connect the fuel pressure gauge carefully to avoid
any fuel spillage.
2. The fuel pump should run about 2 seconds after the
ignition is turned to the ON position.
3. Insert a clear tube attached to the vent valve of the
fuel pressure gauge into a suitable container.
4. Bleed the air from the fuel pressure gauge and hose
until all of the air is bled from the fuel pressure gauge.
5. The ignition switch must be in the OFF position at
least 10 seconds in order to complete the electronic
control module (ECM) shutdown cycle.6. Turn the ignition ON in order to get the fuel pressure
to its maximum level.
7. Allow the fuel pressure to stabilize and then record
this initial pressure reading. Wait until there is no
movement of the needle on the fuel pressure gauge.
8. Follow the manufacturer’s instructions for the use of
the adapter harness. Energize the fuel injector test-
er once and note the fuel pressure drop at its lowest
point. Record this second reading. Subtract it from
the first reading to determine the amount of the fuel
pressure drop.
9. Disconnect the fuel injector tester from the fuel in-
jector.
10. After turning the ignition ON, in order to obtain maxi-
mum pressure once again, make a connection at
the next fuel injector. Energize the fuel injector test-
er and record the fuel pressure reading. Repeat this
procedure for all the injectors.
11. Retest any of the fuel injectors that the pressure
drop exceeds the 10 kPa (1.5 psi) specification.
12. Replace any of the fuel injectors that fail the retest.
13. If the pressure drop of all of the fuel injectors is with-
in 10 kPa (1.5 psi), then the fuel injectors are flowing
normally and no replacement should be necessary.
14. Reconnect the fuel injector harness and review the
symptom diagnostic tables.

ENGINE CONTROLS 1F – 55
DAEWOO M-150 BL2
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
CLEARING TROUBLE CODES
Notice: To prevent Engine Control Module (ECM) dam-
age, the key must be OFF when disconnecting or recon-
necting the power to the ECM (for example battery
cable, ECM pigtail connector, ECM fuse, jumper cables,
etc.).When the ECM sets a Diagnostic Trouble Code
(DTC), the Malfunction Indicator Lamp (MIL) lamp will
be turned on only for type A, B and E but a DTC will be
stored in the ECM’s memory for all types of DTC. If theproblem is intermittent, the MIL will go out after 10 sec-
onds if the fault is no longer present. The DTC will stay
in the ECM’s memory until cleared by scan tool. Remov-
ing battery voltage for 10 seconds will clear some stored
DTCs.
DTCs should be cleared after repairs have been com-
pleted. Some diagnostic tables will tell you to clear the
codes before using the chart. This allows the ECM to set
the DTC while going through the chart, which will help to
find the cause of the problem more quickly.
DIAGNOSTIC TROUBLE CODES
DTCFunctionError TypeIlluminate MIL
P0107Manifold Absolute Pressure Sensor Low VoltageAYES
P0108Manifold Absolute Pressure Sensor High voltageAYES
P0112Intake Air Temperature Sensor Low VoltageEYES
P0113Intake Air Temperature Sensor High voltageEYES
P0117Engine Coolant Temperature Sensor Low VoltageAYES
P0118Engine Coolant Temperature Sensor High voltageAYES
P0122Throttle Position Sensor Low VoltageAYES
P0123Throttle Position Sensor Hig voltageAYES
P0131Oxygen Sensor Low VoltageAYES
P0132Oxygen Sensor High VoltageAYES
P0133Oxygen Sensor No ActivityEYES
P0137Heated Oxygen Sensor Low VoltageEYES
P0138Heated Oxygen Sensor high voltageEYES
P0140Heated Oxygen Sensor No ActivityEYES
P0141Heated Oxygen Sensor Heater MalfuctionEYES
P0171Fuel Trim System Too LeanEYES
P0172Fuel Trim System Too RichEYES
P1230Fuel Pump Relay Low VoltageAYES
P1231Fuel Pump Relay High VoltageAYES
P0261Injector 1 Low VoltageAYES
P0262Injector 1 high voltageAYES
P0264Injector 2 Low VoltageAYES
P0265Injector 2 high voltageAYES
P0267Injector 3 Low VoltageAYES
P0268Injector 3 high voltageAYES
P0300Multifle Cylinder MisfireA/EBLINKING/ON
P1320Crankshatft Segment Period Segment Adaptation At LimitEYES
P1321Crankshatft Segment Period Tooth ErrorEYES
P0327Knock Sensor Circuit FaultEYES
P0335Magnetic Crankshaft Position Sensor Electrical ErrorEYES

1F–56 ENGINE CONTROLS
DAEWOO M-150 BL2
Diagnostic Trouble Codes (Cont’d)
DTCFunctionError TypeIlluminate MIL
P033658X Crankshaft Position Sensor Extra/missing PulseEYES
P033758X Crankshaft Sensor No SignalEYES
P0341Camshaft Position Sensor RationalityEYES
P0342Camshaft Position Sensor No SignalEYES
P0351Ignition Signal Coil A FaultAYES
P0352Ignition Signal Coil B FaultAYES
P0353Ignition Signal Coil C FaultAYES
P1382Rough Road Data Invalid (Non ABS)CnlNO
P1382Rrough Road Data Invalid (ABS)CnlNO
P1385Rough Road Sensor Circuit Fault (Non ABS)CnlNO
P1385Rough Road Sensor Circuit Fault (ABS)CnlNO
P0400Exhaust Gas Recirculation Out of LimitEYES
P1402Exhaust Gas Recirculation BlockedEYES
P1403Exhaust Gas Recirculation Valve FailureEYES
P0404Electric Exhaust Gas Recirculation (EEGR) OpendEYES
P1404Electric Exhaust Gas Recirculation (EEGR) ClosedEYES
P0405EEGR Pintle Position Sensor Low VoltageEYES
P0406EEGR Pintle Position Sensor High voltageEYES
P0420Catalyst Low EfficiencyEYES
P0444EVAP Purge Control Circuit No SignalEYES
P0445EVAP Purge Control Circuit FaultEYES
P0462Fuel Level Sensor Low VoltageCnlNO
P0463Fuel Level Sensor High voltageCnlNO
P0480Low Speed Cooling Fan Relay Circuit Fault (Without A/C)CnlNO
P0480Low Speed Cooling Fan Relay Circuit Fault (With A/C)CnlNO
P0481High Speed Cooling Fan Relay High Voltage (Without A/C)CnlNO
P0481High Speed Cooling Fan Relay High Voltage (With A/C)CnlNO
P0501Vehicle Speed No Signal (M/T Only)AYES
P0505Idle Air Control Valve (IACV) ErrorEYES
P1535Evaporator Temperature Sensor High VoltageCnlNO
P1536Evaporator Temperature Sensor Low VoltageCnlNO
P1537A/C Compressor Relay High VoltageCnlNO
P1538A/C Compressor Relay Low VoltageCnlNO
P0562System Voltage (Engine Side) Too LowCnlNO
P0563System Voltage (Engine Side) Too HighCnlNO
P0601Engine Control Module Checksum ErrorEYES
P0604Engine Control Module RAM ErrorEYES
P0605Engine Control Module NMVY Write ErrorEYES
P1610Main Relay High VoltageAYES
P1611Main Relay Low VoltageAYES
P1628Immobilizer No Successful CommunicationCnlNO
P1629Immobilizer Wrong ComputationCnlNO
P0656Fuel Level Gauge High Circuit FaultCnlNO

ENGINE CONTROLS 1F–57
DAEWOO M-150 BL2
Diagnostic Trouble Codes (Cont’d)
DTCFunctionError TypeIlluminate MIL
P1660Malfunction Indicator Lamp(MIL) High VoltageEYES
P1661Malfunction Indicator Lamp(MIL) Low VoltageEYES

1F–58 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F060
DIAGNOSTIC TROUBLE CODE (DTC) – P0107
MANIFOLD ABSOLUTE PRESSURE SENSOR LOW VOLTAGE
Circuit Description
The engine control module (ECM) uses the Manifold Ab-
solute Pressure (MAP) sensor to control the fuel deliv-
ery and the ignition timing. The MAP sensor measures
the changes in the intake manifold pressure, which re-
sults from engine load (intake manifold vacuum) and the
rpm changes; and converts these into voltage outputs.
The ECM sends a 5 volt-reference voltage to the MAP
sensor. As the manifold pressure changes, the output
voltage of the MAP sensor also changes. By monitoring
the MAP sensor output voltage, the ECM knows the
manifold pressure. A low-pressure (low voltage) output
voltage will be about 1.0 to 1.5 volts at idle, while higher
pressure (high voltage) output voltage will be about 4.5
to 5.0 at wide open throttle (WOT). The MAP sensor is
metric pressure, allowing the ECM to make adjustments
for different altitudes.
Conditions for Setting the DTC

This DTC can be stored in “key-on” status.
(Case A)

When the engine idling.

No throttle position(TP) sensor fail conditions pres-
ent.

Engine speed(rpm) is less than 2,500rpm.

The MAP is less than 15kPA.
(Case A)

When the engine part load.

The engine revolution speed is less than 4,000rpm.

No Throttle Position (TP) Sensor fails conditions
present.

The Throttle Position (TP) angle greather than 20.0
The MAP is less than 15 kPA.
An open or low voltage condition exists.
Action Taken when the DTC Sets

The Malfunction Indicator Lamp (MIL) will illuminate.

The ECM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Freeze Frame and Failure Records buffers.

A history DTC is stored.

The coolant fan turns ON.

The ECM will substitutes a fixed MAP value and use
TP to control the fuel delivery (the scan tool will not
show defaulted)
Conditions for Clearing the MIL/DTC

The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.

A history DTC will clear after 40 consecutive warm-up
cycles without a fault.

DTC(s) can be cleared by using the scan tool.
Diagnostic Aids
With the ignition ON and the engine stopped, the man-
ifold pressure is equal to atmosphere pressure and the
signal voltage will be high.
The ECM as an indication of vehicle altitude uses this
information. Comparison of this reading with a known
good vehicle with the same sensor is a good way to
check the accuracy of a suspect sensor. Readings
should be the same ±0.4volt.
If a DTC P 0107 is intermittent, refer to “Manifold Abso-
lute Pressure Check” in this Section for further diagno-
sis.

ENGINE CONTROLS 1F–59
DAEWOO M-150 BL2
If the connections are OK monitor the manifold absolute
pressure (MAP) sensor signal voltage while moving re-
lated connectors and the wiring harness. If the failure isinduced, the display on the scan tool will change. This
may help to isolate the location of an intermittent mal-
function.
DTC P0107 – Manifold Absolute Pressure Sensor Low Voltage
StepActionValue(s)YesNo
1
Perform an Euro On-Board Diagnostic (EOBD)
System Check.
Is the system check complete?
–
Go to Step 2
Go to
“On-Board
Diagnostic
System Check”
2
1. Connect the scan tool to the data link connector
(DLC).
2. Turn the ignition switch to ON.
Does the scan tool show the manifold absolute
pressure (MAP) sensor voltage above the value
specified?
4VGo to Step 3Go to Step 4
3
1. Disconnect the vacuum line from the MAP
sensor.
2. Apply 88kPA (20in.of Hg) of vacuum to the MAP
sensor.
Does the scan tool show the MAP sensor voltage
within the value specified?
1.0–1.5V
Go to
“Diagnostic
Aids”
Go to Step 4
4
1. Turn the ignition switch to LOCK.
2. Disconnect the MAP sensor connector.
3. Turn the ignition switch to ON.
4. Measure the voltage between the MAP sensor
connector terminals A and C.
Does the voltage measure within the value
specified?
4.5–5.0VGo to Step 5Go to Step 6
5
Connect a fused jumper between the MAP sensor
connector terminals B and C.
Does the scan tool show the MAP sensor voltage
above the value specified?
4VGo to Step 11Go to Step 9
6
Measure the voltage between the MAP sensor
connector terminal A and ground.
Does the voltage measure within the value
specified?
4.5–5.0VGo to Step 7Go to Step 8
7
1. Turn the ignition switch to LOCK.
2. Check for open wires between the MAP sensor
connector terminal A and the ECM connector
terminal 78.
Is the problem found?
–
Go to Step 10Go to Step 12
8
1. Turn the ignition switch to LOCK.
2. Check for an open or short to ground in the wire
between the MAP sensor connector terminal C
and the ECM connector terminal 12.
Is the problem found ?
–
Go to Step 10Go to Step 12
9
1. Turn the ignition switch to LOCK.
2. Check for an open or short to ground in the wire
between the MAP sensor connector terminal B
and the ECM connector terminal 73.
Is the problem found ?
–
Go to Step 10Go to Step 12

1F–60 ENGINE CONTROLS
DAEWOO M-150 BL2
DTC P0107 – Manifold Absolute Pressure Sensor Low Voltage (Cont’d)
StepActionValue(s)YesNo
10
1. Repair the wire or the connector terminal as
needed.
2. Clear any DTCs from the ECM.
3. Perform the diagnostic system check.
Is the repair complete?
–
System OK
–
11
1. Replace the manifold absolute pressure sensor.
2. Clear any DTCs from the ECM.
3. Perform the diagnostic system check.
Is the replacement complete?
–
System OK
–
12Replace the ECM.
Is the replacement complete?–Go to Step 13Go to Step 2
13
Check if any additional DTCs are set.
Are any DTCs displaced that have not been
diagnosed?
–
Go to
applicable DTC
table
System OK

ENGINE CONTROLS 1F–61
DAEWOO M-150 BL2
BLANK

1F–62 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F060
DIAGNOSTIC TROUBLE CODE (DTC) – P0108 MANIFOLD ABSOLUTE
PRESSURE SENSOR HIGH VOLTAGE
Circuit Description
The engine control module (ECM) uses the Manifold Ab-
solute Pressure (MAP) sensor to control the fuel deliv-
ery and the ignition timing. The MAP sensor measures
the changes in the intake manifold pressure, which re-
sults from engine load (intake manifold vacuum) and the
rpm changes; and converts these into voltage outputs.
The ECM sends a 5 volt-reference voltage to the MAP
sensor. As the manifold pressure changes, the output
voltage of the MAP sensor also changes. By monitoring
the MAP sensor output voltage, the ECM knows the
manifold pressure. A low-pressure (low voltage) output
voltage will be about 1.0 to 1.5 volts at idle, while higher
pressure (high voltage) output voltage will be about 4.5
to 4.8 at wide open throttle (WOT). The MAP sensor is
metric pressure, allowing the ECM to make adjustments
for different altitudes.
Conditions for Setting the DTC

This DTC can be stored in “key-on” status.

Engine speed is greater than 2,000rpm.

No throttle position sensor (TPS) fail conditions pres-
ent.

The MAP is greater than 600m bar.

A high voltage condition exists.
Action Taken when the DTC Sets

The Malfunction Indicator Lamp (MIL) will illuminate.

The ECM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Freeze Frame and Failure Records buffers.
A history DTC is stored.

The ECM will substitutes a fixed MAP value and use
TP to control the fuel delivery (the scan tool will not
show defaulted)
Conditions for Clearing the MIL/DTC

The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.

A history DTC will clear after 40 consecutive warm-up
cycles without a fault.

DTC(s) can be cleared by using the scan tool.
Diagnostic Aids
With the ignition ON and the engine stopped, the man-
ifold pressure is equal to atmosphere pressure and the
signal voltage will be high.
The ECM as an indication of vehicle altitude uses this
information. Comparison of this reading with a known
good vehicle with the same sensor is a good way to
check the accuracy of a suspect sensor. Readings
should be the same ±0.4volt.
If a DTC P 0108 is intermittent, refer to “manifold abso-
lute pressure check” in this Section for further diagnosis.
If the connections are OK monitor the manifold absolute
pressure(MAP) sensor signal voltage while moving re-
lated connectors and the wiring harness. If the failure is
induced, the display on the scan tool will change. This
may help to isolate the location of an intermittent mal-
function.