battery DAEWOO MATIZ 2003 Service Owners Manual

ENGINE CONTROLS 1F–193
DAEWOO M-150 BL2
DTC P0404 – Electric Exhaust Gas Recirculation Opened
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. Turn the ignition switch to with the engine OFF.
2. Install the scan tool.
3. Command the electric exhaust gas recirculation
(EEGR) valve to the specified values.
Does the Actual EEGR Position follow the desired
EEGR position?
25%, 50%,
75%, 100%
Go to Step 19Go to Step 3
3
1. Turn the ignition switch to ON.
2. Disconnect the EEGR valve electrical connector.
3. With a test light connected to B+, probe the
ground circuit to the EEGR valve.
Does the test light illuminate?
–
Go to Step 4Go to Step 5
4
1. Connect the test light to ground.
2. Probe the EEGR control circuit at terminal 1 to
the EEGR valve.
3. Command the EEGR valve to the specified
values 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
5
Repair the open or poor connection in the EEGR
ground circuit.
Is the repair complete?
–
Go to Step 19
–
6
With a test light still connected to ground, probe the
signal circuit at terminal 1.
Does the test light illuminate?
–
Go to Step 8Go to Step 9
7
With a test light still connected to ground, again
probe the signal circuit without commanding the
EEGR valve with the scan tool.
Does the test light illuminate?
–
Go to Step 10Go to Step 11
8
Check the signal circuit for a short to voltage and
repair as necessary.
Is a repair necessary?
–
Go to Step 19Go to Step 12
9
With a digital voltmeter (DVM) connected to ground,
probe the 5V reference circuit at terminal 3.
Is the voltage measured near the specified value?
5VGo to Step 13Go to Step 14
10
Check the control circuit for a short to battery
voltage and repair as necessary.
Is a repair necessary?
–
Go to Step 19Go to Step 12
11
Connect the test light to B+ and again probe the
control 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–
13
Check the EEGR 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

1F–194 ENGINE CONTROLS
DAEWOO M-150 BL2
DTC P0404 – Electric Exhaust Gas Recirculation Opened (Cont’d)
StepActionValue(s)YesNo
14
Check the 5V reference circuit for a shortage to
battery voltage and repair as necessary.
Is a repair necessary?
–
Go to Step 19Go to Step 12
15
Check the control circuit for a shortage to ground
and repair as necessary.
Is a repair necessary?
–
Go to Step 19Go to Step 12
16
Check the control circuit for an open or poor
connection at the EEGR valve electrical connector
and repair as necessary.
Is a repair necessary?
–
Go to Step 19Go to Step 18
17Replace the EEGR valve.
Is the replacement complete?–Go to Step 19–
18
Check the ECM electrical connector for a poor
connection and repair as necessary.
Is a repair necessary?
–
Go to Step 19Go to Step 12
19
1. 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
20
Check if any additional DTCs are set.
Are any DTCs displayed that have not been
diagnosed?
–
Go to
Applicable DTC
table
System OK

1F–196 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F230
DIAGNOSTIC TROUBLE CODE (DTC) – P1404 ELECTRIC EXHAUST GAS
RECIRCULATION CLOSED
Circuit Description
An Electric Exhaust Gas Re-circulation (EEGR) system
is used to lower oxides of nitrogen (NOX) emission lev-
els caused by high combustion temperatures. It a ac-
complishes this by feeding small amounts of exhaust
gases back into the combustion chamber. When the air/
fuel mixture is diluted with the exhaust gases, combus-
tion temperatures are reduced.
A linear EEGR valve is used on this system. The linear
EEGR 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 fhrough 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 Abso-
lute Pressure (MAP) sensor. The ECM then commands
the EEGR valve to operate when necessary by control-
ling an ignition signal through the ECM. This can be
monitored on a scan tool as the Desired EEGR position.
The ECM monitors the results of its command through a
feedback signal. By sending a 5 volt reference and a
ground to the EEGR valve, a voltage signal representing
the EEGR valve pintle position is sent to the ECM. This
feedback signal can also be monitored on a scan tool
and is the actual position of the EEGR pintle. The actual
EEGR position should always be near the commanded
or Desired EEGR position.
ThisDiagnostic Trouble Code(DTC) will detect an open
or short circuit.Conditions for Setting THE DTC

EEGR circuit high voltage.
Action Taken When The DTCs 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.

EEGR is disabled.
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.

Disconnecting the ECM battery feed for more than 10
seconds.
Diagnostic Aids
Due to moisture associated with exhaust systems, the
EEGR 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 EEGR and desired EEGR posi-
tions on a cold vehicle with a scan tool, the fault can be
easily verified. Check the Freeze Frame data to deter-
mine if the DTC set when the vehicle was cold by view-
ing the Engine Coolant Temperature (ECT).

1F–200 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F230
DIAGNOSTIC TROUBLE CODE (DTC) – P0405 EEGR PINTLE POSITION
SENSOR LOW VOLTAGE
Circuit Description
An Electric Exhaust Gas Re-circulation (EEGR) system
is used to lower oxides of nitrogen (NOX) emission lev-
els caused by high combustion temperatures. It a ac-
complishes this by feeding small amounts of exhaust
gases back into the combustion chamber. When the air/
fuel mixture is diluted with the exhaust gases, combus-
tion temperatures are reduced.
A linear EEGR valve is used on this system. The linear
EEGR 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 fhrough 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 Abso-
lute Pressure (MAP) sensor. The ECM then commands
the EEGR valve to operate when necessary by control-
ling an ignition signal through the ECM. This can be
monitored on a scan tool as the Desired EEGR position.
The ECM monitors the results of its command through a
feedback signal. By sending a 5 volt reference and a
ground to the EEGR valve, a voltage signal representing
the EEGR valve pintle position is sent to the ECM. This
feedback signal can also be monitored on a scan tool
and is the actual position of the EEGR pintle. The actual
EEGR position should always be near the commanded
or Desired EEGR position.
ThisDiagnostic Trouble Code(DTC) will detect an open
or short circuit.Conditions for Setting THE DTC

EEGR voltage is less than 0.01V.

EEGR potentiometer circuit low voltage.
Action Taken When The DTCs 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.

EEGR is disabled.
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.

Disconnecting the ECM battery feed for more than 10
seconds.
Diagnostic Aids
Due to moisture associated with exhaust systems, the
EEGR 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 EEGR and desired EEGR posi-
tions on a cold vehicle with a scan tool, the fault can be
easily verified. Check the Freeze Frame data to deter-
mine if the DTC set when the vehicle was cold by view-
ing the Engine Coolant Temperature (ECT).

ENGINE CONTROLS 1F–211
DAEWOO M-150 BL2

The EVAP system in unable to achieve or maintain
vacuum during the diagnostic test. The amount of
decay will vary within the fuel level.
Action Taken When The DTCs 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.
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
Although this DTC is considered a type. A diagnostic, it
acts like a type B diagnostic under certain conditions.
Whenever this diagnostic reports the system has
passed, or if the battery is disconnected, the diagnostic
must fail twice before setting a DTC. The initial failure is
not reported to the diagnostic executive or displayed on
a scan tool. A passing system always reports to the
diagnostic executive immediately.Check for the following conditions :

Missing or damaged fuel cap.

Missing or damaged O-rings at fuel vapor and EVAP
purge line canister fittings.

Cracked or punctured EVAP canister.

Damaged source vacuum line, EVAP purge line,
EVAP vent hose or fuel tank vapor line.

Poor connection at the ECM. Inspect the harness
connectors for the following conditions.

Backed-out terminals.

Improper mating.

Broken locks.

Improperly formed.

Damaged terminals.

Poor terminal-to-wire connection.

Damaged harness. Inspect the wiring harness to the
EVAP vent solenoid, EVAP canister purge valve, and
the fuel tank pressure sensor for an intermittent open
or short circuit.

Kinked, pinched or plugged vacuum source, EVAP
purge, or fuel tank vapor line. Verify that the lines are
not restricted.

1F–212 ENGINE CONTROLS
DAEWOO M-150 BL2
DTC P0444 – EVAP Purge Control Circuit No Signal
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. Disconnect the evaporative emission (EVAP)
canister purge valve connector.
2. Connect a test light between the EVAP canister
purge valve connector terminal 2 and battery
positive.
Is the test light ON?
–
Go to Step 3Go to Step 5
3
1. Disconnect the ECM connector.
2. Connect a test light between the ECM connector
terminal 66 and ground.
Is the test light ON?
–
Go to Step 4Go to Step 6
4
1. Repair the line break in the wire between the
EVAP canister purge valve connector 1 and the
ECM connector terminal 66.
2. Clear any Diagnostic Trouble Codes (DTCs) from
the ECM.
3. Perform the diagnostic system check.
Is the repair complete?
–
System OK
–
5
1. Repair the line break in the wire between the
EVAP canister purge valve connector 2 and the
main relay connector terminal 87.
2. Clear any Diagnostic Trouble Codes (DTCs) from
the ECM.
3. Perform the diagnostic system check.
Is the repair complete?
–
System OK
–
6
1. Replace the ECM.
2. Perform the diagnostic system check.
Is the repair complete?
–
Go to Step 7
–
7
1. 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 7Go to Step 2
8
Check if any additional DTCs are set.
Are any DTCs displayed that have not been
diagnosed?
–
Go to
Applicable DTC
table
System OK

ENGINE CONTROLS 1F–215
DAEWOO M-150 BL2

The EVAP system in unable to achieve or maintain
vacuum during the diagnostic test. The amount of
decay will vary within the fuel level.
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.

Coolant fan turns ON.
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
Although this DTC is considered a type. A diagnostic, it
acts like a type B diagnostic under certain conditions.
Whenever this diagnostic reports the system has
passed, or if the battery is disconnected, the diagnostic
must fail twice before setting a DTC. The initial failure is
not reported to the diagnostic executive or displayed ona scan tool. A passing system always reports to the
diagnostic executive immediately.
Check for the following conditions :
Missing or damaged fuel cap.
Missing or damaged O-rings at fuel vapor and EVAP
purge line canister fittings.
Cracked or punctured EVAP canister.
Damaged source vacuum line, EVAP purge line, EVAP
vent hose or fuel tank vapor line.
Poor connection at the ECM. Inspect the harness con-
nectors for the following conditions.

Backed-out terminals.

Improper mating.

Broken locks.

Improperly formed.

Damaged terminals.

Poor terminal-to-wire connection.

Damaged harness. Inspect the wiring harness to the
EVAP vent solenoid, EVAP canister purge valve, and
the fuel tank pressure sensor for an intermittent open
or short circuit.

Kinked, pinched or plugged vacuum source, EVAP
purge, or fuel tank vapor line. Verify that the lines are
not restricted.
DTC P0445 – EVAP Purge Control Circuit Fault
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. Disconnect the evaporative emission (EVAP)
canister purge valve connector.
2. Measure the resistance of the EVAP canister
purge valve connector.
Does the resistance measure near within the value
specified?
30ΩGo to Step 3Go to Step 9
3
Connect a test light between EVAP canister purge
valve connector terminal 2 and ground.
Is the test light ON?
–
Go to Step 4Go to Step 6
4
1. Disconnect the ECM connector.
2. Connect a test light between the ECM connector
terminal 66 and ground.
Is the test light ON?
–
Go to Step 5Go to Step 7

1F–216 ENGINE CONTROLS
DAEWOO M-150 BL2
DTC P0445 – EVAP Purge Control Circuit Fault (Cont’d)
StepActionValue(s)YesNo
5
1. Repair the high voltage or ground in the wire
between the EVAP canister purge valve
connector terminal 1 and the ECM connector
terminal 66.
2. Clear any Diagnostic Trouble Codes (DTCs) from
the ECM.
3. Perform the diagnostic system check.
Is the repair complete?
–
System OK
–
6
1. Disconnect the EVAP canister purge valve
connector.
2. Connect a test light between the EVAP canister
purge valve connector terminal 2 and battery.
Is the test light ON?
–
Go to Step 7Go to Step 9
7
1. Disconnect the ECM connector.
2. Connect a test light between the ECM connector
terminal 65 and ground.
Is the test light ON?
–
Go to Step 8Go to Step 10
8
1. Repair the low voltage in the wire between the
EVAP canister purge valve connector terminal 1
and the ECM connector terminal 66.
2. Clear any Diagnostic Trouble Codes (DTCs) from
the ECM.
3. Perform the diagnostic system check.
Is the repair complete?
–
System OK
–
9
1. Replace the EVAP canister purge valve.
2. Clear any Diagnostic Trouble Codes (DTCs) from
the ECM.
3. Perform the diagnostic system check.
Is the repair complete?
–
Go to Step 10
–
10
1. 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 11Go to Step 2
11
Check if any additional DTCs are set.
Are any DTCs displayed that have not been
diagnosed?
–
Go to
Applicable DTC
table
System OK

ENGINE CONTROLS 1F–223
DAEWOO M-150 BL2
DTC P0463 – Fuel Level Sensor High 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. Turn the ignition switch to ON.
2. Install a scan tool.
3. Operate the vehicle within Freeze Frame
conditions as noted.
Is the Diagnostic Trouble Code (DTC) P0463 set?
–
Go to Step 3
Go to
“Diagnostic
Aids”
3
1. Disconnect the fuel sender electrical connector
from the fuel pump.
2. Using a digital voltmeter (DVM), measure the
voltage in the signal circuit at terminal 1.
Is the voltage within the specified value?
0.2–4.9VGo to Step 4Go to Step 6
4
Check for a proper ground connection at the fuel
tank and repair as necessary.
Is a repair necessary?
–
Go to Step 11Go to Step 5
5
1. Remove the fuel sender from the fuel tank.
2. Reconnect the fuel pump electrical connector.
3. Monitor the Fuel Level Sensor parameter on the
scan tool while moving the Fuel Level Sensor
float from the empty position to the full position.
4. Repeat the procedure several times.
Does the Fuel Level Sensor value on the scan tool
increase and then decrease steadily when the float
is moved?
–
Go to
“Diagnostic
Aids”
Go to Step 8
6
Check for an open or short to battery voltage in the
Fuel Level Sensor circuit and repair as necessary.
Is the repair necessary?
–
Go to Step 11Go to Step 9
7
Repair the open or short to battery voltage in the
Fuel Level Sensor circuit between the Fuel Level
Sensor harness connector and the Fuel Level
Sensor.
Is the repair complete?
–
Go to Step 11
–
8Replace the fuel sender assembly.
Is the replacement complete?–Go to Step 11–
9
1. Connect the fuel pump electrical connector.
2. Disconnect the engine control module(ECM)
connector.
3. Using a digital voltmeter (DVM) measure the
voltage in the signal circuit, at terminal 81.
Does the DVM read within the specified value?
0.2–4.9VGo to Step 10
Go to
section 9E,
Instrumenta-
tion/Driver
Information
10Replace the ECM.
Is the repair complete?–Go to Step 11–
11
1. 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 12Go to Step 2

1F–226 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F090
DIAGNOSTIC TROUBLE CODE (DTC) – P0480 LOW SPEED COOLING FAN
RELAY CIRCUIT FAULT (WITHOUT A/C)
Circuit Description
Ignition voltage is supplied directly to the cooling fan
relay coil. The engine control module(ECM) controls the
relay by grounding the control circuit via an internal
switch called a driver. The primary function of the driver
is supply the ground for the component being controlled.
Each driver has a fault line which is monitored by the
ECM. When the ECM is commanding a component ON,
the voltage of the control circuit should be low (near
0volts). When the ECM is commanding the control cir-
cuit to a component OFF, the voltage potential of the cir-
cuit should be high(near battery voltage). If the fault
detection circuit senses a voltage other than what is ex-
pected, the fault line status will change causing the DTC
to set.
The relay is used to control the high current flow to the
cooling fan motors. This allows the ECM driver to only
have to handle the relatively low current used by the
relay.
Conditions for Setting the DTC

Diagnostic Trouble Codes (DTCs) P0117, P0118 not
set.

Ignition ON.
Ignition voltage is greater than 10 volts.

Engine run time is greater than 5 seconds.
Action Taken When the DTC Sets

The Malfunction Indicator Lamp (MIL) will not illumi-
nate.

The ECM will store conditions which were present
when the DTC was set as Failure Records data only.

This information will not be stored in the Freeze
Frame data.
Conditions for Clearing the MIL/DTC

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
Using Freeze Frame and/or failure records data may aid
in locating an intermittent condition. If the DTC cannot
be duplicated, the information included in the Freeze
Frame and/or failure records data can be useful in deter-
mining how many miles since the DTC set. The fail
counter and Pass Counter can also be used to deter-
mine how many ignition cycles the diagnostics reported