egr DAEWOO LACETTI 2004 Service Manual PDF

1F – 38IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
10Replace the EGR valve.
Is the replacement complete?–Go to Step 19–
11Locate and repair the short to voltage in the MAP
sensor signal circuit.
Is the repair complete?–Go to Step 19–
12Locate and repair the short to voltage in the TP sen-
sor signal circuit.
Is the repair complete?–Go to Step 19–
13Locate and repair the short to voltage in the IAT sen-
sor signal circuit.
Is the repair complete?–Go to Step 19–
14Locate and repair the short to voltage in the ECT
sensor signal circuit.
Is the repair complete?–Go to Step 19–
15Locate and repair the short to voltage in the EGR
Pintle Position sensor circuit.
Is the repair complete?–Go to Step 19–
16Measure the voltage of the fuel tank pressure sensor
signal circuit between the ECM harness connector
and ground.
Does the voltage near the specified value?0 VGo to Step 18Go to Step 17
17Locate and repair the short to voltage in the fuel tank
pressure sensor signal circuit.
Is the replacement complete?–Go to Step 19–
18Replace the ECM.
Is the repair complete?–Go to Step 19
191. Using the scan tool, clear the Diagnostic
Trouble Codes (DTCs).
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for
setting the DTCs as specified in the supporting
text.
Does the scan tool indicate that this diagnostic ran
and passed?–Go to Step 20Go to Step 2
22Check if any additional DTCs are set.
Are any DTCs displayed that have not been diag-
nosed?–Go to applica-
ble DTC tableSystem OK

1F – 112IENGINE CONTROLS
DAEWOO V–121 BL4
DTCIlluminate MIL Error
Type Function
P0300Multiple Cylinder Misfire (Increase Emission)EYES
P0327Knock Sensor Circuit Fault (1.4L DOHC)CnlNO
P0327Knock Sensor Circuit Fault (1.6L DOHC)EYES
P0335Magnetic Crankshaft Position Sensor Electrical ErrorEYES
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
P0400Exhaust Gas Recirculation Out of LimitEYES
P0404Exhaust Gas Recirculation (EGR) PpendEYES
P0405EGR Pintle Position Sensor Low VoltageEYES
P0406EGR Pintle Position Sensor High voltageEYES
P0420Catalyst Low EfficiencyAYES
P0444EVAP Purge Control Circuit No SignalEYES
P0445EVAP Purge Control Circuit FaultEYES
P0462Fuel Level Sensor Low Voltage (1.6L DOHC Only)CnlNO
P0463Fuel Level Sensor High Voltage (1.6L DOHC Only)CnlNO
P0480Low Speed Cooling Fan Relay Circuit Fault (1.4L DOHC)EYES
P0480Low Speed Cooling Fan Relay Circuit Fault (1.6L DOHC)CnlNO
P0481High Speed Cooling Fan Relay High Voltage (1.4L DOHC)EYES
P0481High Speed Cooling Fan Relay High Voltage (1.6L DOHC)CnlNO
P0501Vehicle Speed No Signal (M/T Only)AYES
P0510Throttle Positon Switch Circuit Fault (1.4L DOHC)CnlNO
P0510Throttle Positon Switch Circuit Fault (1.6L DOHC)AYES
P0532A/C Pressure Sensor Low VoltageCnlNO
P0533A/C Pressure Sensor High 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 INMVY Write ErrorEYES
P0656Fuel Level Gauge High Circuit FaultCnlNO
P1181Variable Intake Manifold Solenoid Low VoltageEYES
P1182Variable Intake Manifold Solenoid High VoltageEYES
P1230Fuel Pump Relay Low Voltage (1.4L DOHC)CnlNO
P1230Fuel Pump Relay Low Voltage (1.6L DOHC)AYES
P1231Fuel Pump Relay High Voltage (1.4L DOHC)CnlNO
P1231Fuel Pump Relay High Voltage (1.6L DOHC)AYES
P1320Crankshaft Segment Period Segment Adaptation At LimitEYES

ENGINE CONTROLS 1F – 113
DAEWOO V–121 BL4
DTCIlluminate MIL Error
Type Function
P1321Crankshaft Segment Period Tooth ErrorEYES
P1382Rough Road Data Invalid (Non ABS)CnlNO
P1382Rrough Road Data Invalid (ABS)CnlNO
P1385Rough Road Sensor Circuit Fault (Non ABS)CnlNO
P1402Exhaust Gas Recirculation BlockedEYES
P1403Exhaust Gas Recirculation Valve FailureEYES
P1404Exhaust Gas Recirculation (EGR) ClosedEYES
P1511Idle Charge Actuactor Circuit FaultEYES
P1512Idle Charge Actuactor Mechanical ErrorEYES
P1513Idle Charge Actuactor Functionnal ErrorCnlNO
P1537A/C Compressor Relay High VoltageCnlNO
P1538A/C Compressor Relay Low VoltageCnlNO
P1610Main Relay High Voltage (1.4L DOHC)CnlNO
P1610Main Relay High Voltage (1.6L DOHC)AYES
P1611Main Relay Low Voltage (1.4L DOHC)CnlNO
P1611Main Relay Low Voltage (1.6L DOHC)AYES
P1628Immobilizer No Successful CommunicationCnlNO
P1629Immobilizer Wrong ComputationCnlNO
P1660Malfunction Indicator Lamp(MIL) High VoltageEYES
P1661Malfunction Indicator Lamp(MIL) Low VoltageEYES

1F – 216IENGINE CONTROLS
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0352
IGNITION SIGNAL COIL B FAULT
Circuit Description
The engine control module (ECM) provides a ground for
the electronic spark timing 3 circuit. When the ECM re-
moves the ground path of the ignition primary coil, the
magnetic field produced by the coil collapses. The collaps-
ing magnetic field produces a voltage in the secondary
coil, which fires the spark plug. The circuit between the
ECM and the electronic ignition system is monitored for an
open circuit, short to voltage, and low voltage. When the
ECM detects a problem in the spark timing 3 circuit, it will
set DTC P0352.
Conditions for Setting the DTC
S The ignition signal coil B circuit is an open or a
short ground or short to battery condition exists.
Action Taken When the DTC Sets
S The Malfunction Indicator Lamp (MIL) will illumi-
nate.
S 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.
S A history DTC is stored.S The ECM will default to 6 degree timing.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm
up cycles without a fault.
S Using the scan tool can clear DTC(s).
S Disconnecting the ECM battery feed for 10 sec-
onds.
Diagnostic Aids
Check and correct any abnormal engine noise before us-
ing the diagnostic table.
Any circuitry that is suspected as causing engine noise
complaint should be thoroughly checked for the following
conditions :
S Backed–out terminals
S Improper mating
S Broken locks
S Improperly formed
S Damaged terminals
S Poor terminal–to–wire connection
S Physical damage to the wiring harness

1F – 218IENGINE CONTROLS
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0400
EXHAUST GAS RECIRCULATION OUT OF LIMIT
Circuit Description
An Exhaust Gas Re–circulation (EGR) system is used to
lower oxides of nitrogen (NOx) emission levels caused by
high combustion temperatures. It accomplishes this by
feeding small amounts of exhaust gases back into the
combustion chamber. When the air/fuel mixture is diluted
with the exhaust gases, combustion temperatures are re-
duced.
A linear EGR valve is used on this system. The linear EGR
valve is designed to accurately supply exhaust gases to
the engine without the use of intake manifold vacuum. The
valve controls exhaust flow going into the intake manifold
from the exhaust manifold through an orifice with a engine
control module(ECM) controlled pintle. The ECM controls
the pintle position using inputs from the Throttle Position
(TP) and the Manifold Absolute Pressure (MAP) sensor.
The ECM then commands the EGR valve to operate when
necessary by controlling an ignition signal through the
ECM. This can be monitored on a scan tool as the Desired
EGR position.
The ECM monitors the results of its command through a
feedback signal. By sending a 5 volt reference and a
ground to the EGR valve, a voltage signal representing the
EGR valve pintle position is sent to the ECM. This feed-back signal can also be monitored on a scan tool and is the
actual position of the EGR pintle. The actual EGR position
should always be near the commanded or Desired EGR
position.
This Diagnostic Trouble Code(DTC) will detect an open or
short circuit.
Conditions for Setting the DTC
S The vehicle is part load.
S The engine controls system is in closed loop.
S Engine Coolant Temperature (ECT) is higher than
70°C (158°F). (1.4L DOHC)
S Engine Coolant Temperature (ECT) is higher than
60°C (140°F). (1.6L DOHC)
S Mass Air Flow is between 120~230mg/tdc.
(1.4L DOHC)
S Mass Air Flow is between 71~174mg/tdc.
(1.6L DOHC)
S Engine Speed is Between 1,800~2,400rpm.
(1.4L DOHC)
S Engine Speed is Between 1,950~2,600rpm.
(1.6L DOHC)
S Intake Air Temperature(IAT) is higher than
15°C(59°F).
S Manifold Absolute Pressure is greater than 75kPA.
S The EGR is higher than 10%.

ENGINE CONTROLS 1F – 219
DAEWOO V–121 BL4
S DTCs P0107, P0108, P0112, P0113, P0117,
P0118, P0122, P0123, P0131, P0300, P0335,
P0336, P0341, P0342, P1671, P1672, P1673 are
NOT SET.
Action Taken When the DTC Sets
S The Malfunction Indicator Lamp (MIL) will illuminate
after three consecutive trip with a fail.
S The ECM will record operating conditions at the
time the diagnostic fail. This information will be
stored in the Freeze Frame and Failure Recordsbuffers.
S A history DTC is stored.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.
S Disconnecting the ECM battery feed for more than
10 seconds.
DTC P0400 – Exhaust Gas Recirculation Out of Limit
StepActionValue(s)YesNo
1Perform an Euro On–Board Diagnostic (EOBD)
System Check.
Is the system check complete?–Go to Step 2Go to
”On–Board
Diagnostic Sys-
tem Check”
21. Turn the ignition switch to with the engine OFF.
2. Install the scan tool.
3. Command the exhaust gas recirculation (EGR)
valve to the specified values.
Does the Actual EGR Position follow the desired
EGR position?25%, 50%
75%, 100%Go to Step 19Go to Step 3
31. Turn the ignition switch to ON.
2. Disconnect the EGR valve electrical connector.
3. With a test light connected to B+, probe the
ground circuit to the EGR valve.
Does the test light illuminate?–Go to Step 4Go to Step 5
41. Connect the test light to ground.
2. Probe the EGR control circuit at terminal 3 to
the EGR valve.
3. Command the EGR valve to the specified val-
ues using a scan tool.
After the command is raised, does the test light glow
brighter, flash or maintain a steady glow?25%, 50%
75%, 100%Go to Step 6Go to Step 7
5Repair the open or poor connection in the EGR
ground circuit.
Is the repair complete?–Go to Step 19–
6With a test light still connected to ground, probe the
signal circuit at terminal 3.
Does the test light illuminate?–Go to Step 8Go to Step 9
7With a test light still connected to ground, again
probe the signal circuit without commanding the
EGR valve with the scan tool.
Does the test light illuminate?–Go to Step 10Go to Step 11
8Check the signal circuit for a short to voltage and re-
pair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
9With a digital voltmeter (DVM) connected to ground,
probe the 5V reference circuit at terminal 1.
Is the voltage measured near the specified value?5VGo to Step 13Go to Step 14

1F – 220IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
10Check the control circuit for a short to battery voltage
and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
11Connect the test light to B+ and again probe the con-
trol circuit at terminal 4.
Does the test light illuminate?–Go to Step 15Go to Step 16
12Replace the engine control module (ECM).
Is the replacement complete?–Go to Step 19–
13Check the EGR ground circuit for a poor connection
or proper terminal tension at the ECM and repair as
necessary.
Is a repair necessary?–Go to Step 19Go to Step 17
14Check the 5V reference circuit for a shortage to bat-
tery voltage and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
15Check the control circuit for a shortage to ground
and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
16Check the control circuit for an open or poor connec-
tion at the EGR valve electrical connector and repair
as necessary.
Is a repair necessary?–Go to Step 19Go to Step 18
17Replace the EGR valve.
Is the replacement complete?–Go to Step 19–
18Check the ECM electrical connector for a poor con-
nection and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
191. Using the scan tool, clear the Diagnostic
Trouble Codes (DTCs).
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for
setting the DTC as specifiec in the supporting
text.
Does the scan tool indicate that this diagnostic ran
and passed?–Go to Step 20Go to Step 2
20Check if any additional DTCs are set.
Are any DTCs displayed that have not been diag-
nosed?–Go to
Applicable DTC
tableSystem OK

ENGINE CONTROLS 1F – 221
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0404
EXHAUST GAS RECIRCULATION OPENED
Circuit Description
An Exhaust Gas Re–circulation (EGR) system is used to
lower oxides of nitrogen (NOx) emission levels caused by
high combustion temperatures. It accomplishes this by
feeding small amounts of exhaust gases back into the
combustion chamber. When the air/fuel mixture is diluted
with the exhaust gases, combustion temperatures are re-
duced.
A linear EGR valve is used on this system. The linear EGR
valve is designed to accurately supply exhaust gases to
the engine without the use of intake manifold vacuum. The
valve controls exhaust flow going into the intake manifold
from the exhaust manifold through an orifice with a engine
control module(ECM) controlled pintle. The ECM controls
the pintle position using inputs from the Throttle Position
(TP) and the Manifold Absolute Pressure (MAP) sensor.
The ECM then commands the EGR valve to operate when
necessary by controlling an ignition signal through the
ECM. This can be monitored on a scan tool as the Desired
EGR position.
The ECM monitors the results of its command through a
feedback signal. By sending a 5 volt reference and a
ground to the EGR valve, a voltage signal representing the
EGR valve pintle position is sent to the ECM. This feed-back signal can also be monitored on a scan tool and is the
actual position of the EGR pintle. The actual EGR position
should always be near the commanded or Desired EGR
position.
This Diagnostic Trouble Code(DTC) will detect an open or
short circuit.
Conditions for Setting the DTC
S EGR circuit is a short to ground or an open condi-
tion exist.
Action Taken When the DTC Sets
S The Malfunction Indicator Lamp (MIL) will illuminate
after three consecutive trip with a fail.
S The ECM will record operating conditions at the
time the diagnostic fail. This information will be
stored in the Freeze Frame and Failure Records
buffers.
S A history DTC is stored.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.

1F – 222IENGINE CONTROLS
DAEWOO V–121 BL4
S Disconnecting the ECM battery feed for more than
10 seconds.
Diagnostic Aids
Due to moisture associated with exhaust systems, the
EGR valve may freeze and stick in cold weather at times.
After the vehicle is brought into a warm shop for repairs,the valve warms and the problem disappears. By watching
the Actual EGR and desired EGR positions on a cold ve-
hicle with a scan tool, the fault can be easily verified.
Check the Freeze Frame data to determine if the DTC set
when the vehicle was cold by viewing the Engine Coolant
Temperature (ECT).
DTC P0404 – Exhaust Gas Recirculation Opened
StepActionValue(s)YesNo
1Perform an Euro On–Board Diagnostic (EOBD)
System Check.
Is the system check complete?–Go to Step 2Go to
”On–Board
Diagnostic Sys-
tem Check”
21. Turn the ignition switch to with the engine OFF.
2. Install the scan tool.
3. Command the exhaust gas recirculation (EGR)
valve to the specified values.
Does the Actual EGR Position follow the desired
EGR position?25%, 50%
75%, 100%Go to Step 19Go to Step 3
31. Turn the ignition switch to ON.
2. Disconnect the EGR valve electrical connector.
3. With a test light connected to B+, probe the
ground circuit to the EGR valve.
Does the test light illuminate?–Go to Step 4Go to Step 5
41. Connect the test light to ground.
2. Probe the EGR control circuit at terminal 3 to
the EGR valve.
3. Command the EGR valve to the specified val-
ues using a scan tool.
After the command is raised, does the test light glow
brighter, flash or maintain a steady glow?25%, 50%
75%, 100%Go to Step 6Go to Step 7
5Repair the open or poor connection in the EGR
ground circuit.
Is the repair complete?–Go to Step 19–
6With a test light still connected to ground, probe the
signal circuit at terminal 3.
Does the test light illuminate?–Go to Step 8Go to Step 9
7With a test light still connected to ground, again
probe the signal circuit without commanding the
EGR valve with the scan tool.
Does the test light illuminate?–Go to Step 10Go to Step 11
8Check the signal circuit for a short to voltage and re-
pair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
9With a digital voltmeter (DVM) connected to ground,
probe the 5V reference circuit at terminal 1.
Is the voltage measured near the specified value?5VGo to Step 13Go to Step 14
10Check the control circuit for a short to battery voltage
and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
11Connect the test light to B+ and again probe the con-
trol circuit at terminal 4.
Does the test light illuminate?–Go to Step 15Go to Step 16

ENGINE CONTROLS 1F – 223
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
12Replace the engine control module (ECM).
Is the replacement complete?–Go to Step 19–
13Check the EGR ground circuit for a poor connection
or proper terminal tension at the ECM and repair as
necessary.
Is a repair necessary?–Go to Step 19Go to Step 17
14Check the 5V reference circuit for a shortage to bat-
tery voltage and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
15Check the control circuit for a shortage to ground
and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
16Check the control circuit for an open or poor connec-
tion at the EGR valve electrical connector and repair
as necessary.
Is a repair necessary?–Go to Step 19Go to Step 18
17Replace the EGR valve.
Is the replacement complete?–Go to Step 19–
18Check the ECM electrical connector for a poor con-
nection and repair as necessary.
Is a repair necessary?–Go to Step 19Go to Step 12
191. Using the scan tool, clear the Diagnostic
Trouble Codes (DTCs).
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for
setting the DTC as specifiec in the supporting
text.
Does the scan tool indicate that this diagnostic ran
and passed?–Go to Step 20Go to Step 2
20Check if any additional DTCs are set.
Are any DTCs displayed that have not been diag-
nosed?–Go to
Applicable DTC
tableSystem OK