DAEWOO MATIZ 2003 Service Repair Manual

ENGINE CONTROLS 1F–33
DAEWOO M-150 BL2
Malfunction Indicator Lamp On Steady
StepActionValue(s)YesNo
1
Perform an Euro On-Board Diagnostic (EOBD)
System Check.
Is the check complete.
–
Go to Step 2
Go to “Euro
On-Board
Diagnostic
System Check”
2
1. Turn the ignition OFF.
2. Install the scan tool.
3. Command the Malfunction Indicator Lamp (MIL)
on and off.
Does the MIL turn on and off when commanded?
–
Go to Step 7Go to Step 3
3
1. Turn the ignition OFF.
2. Disconnect the engine control module (ECM)
connector.
3. Turn the ignition ON.
Is the MIL off?
–
Go to Step 6Go to Step 4
4
Check the MIL control circuit for a short to ground
and repair as needed.
Is a repair necessary?
–
Go to Step 7Go to Step 5
5
Replace the instrument panel cluster. Refer to
Section 9E, Instrumentation/Driver Information.
Is the repair complete?
–
Go to Step 7
–
6Replace the ECM.
Is the repair complete?–Go to Step 7–
7
1. Using the scan tool, clear the Diagnostic Trouble
Codes(DTCs).
2. Attempt to start the engine.
Does the engine start and continue to run?
–
Go to Step 8Go to Step 1
8
Allow the engine to idle until normal operating
temperature is reached.
Check if any DTCs are set.
Are any DTCs displayed that have not been
diagnosed?
–
Go to applicable
DTC table
System OK

1F–34 ENGINE CONTROLS
DAEWOO M-150 BL2
FUEL SYSTEM DIAGNOSIS
Circuit Description
The fuel pump is an in-tank type mounted to a fuel send-
er assembly. The fuel pump will remain on as long as the
engine is cranking or running and the Engine Control
Module (ECM) is receiving reference pulses from the
crankshaft position (CKP) sensor. If there are no refer-
ence pulses, the ECM will turn off the fuel pump two sec-
onds after the ignition switch is turned ON or two
seconds after the engine stops running. The fuel pump
delivers fuel to the fuel rail and the fuel injectors, where
the fuel system pressure is controlled from 380 kPa (55
psi) by the fuel pressure regulator. The excess fuel is re-
turned to the fuel tank.
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury orfire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
Caution: Do not pinch or restrict nylon fuel lines.
Damage to the lines could cause a fuel leak, result-
ing in possible fire or personal injury.
Fuel Pressure Relief Procedure
1. Remove the fuel cap.
2. Remove the fuel pump fuse EF23 from the engine
fuse block.
3. Start the engine and allow the engine to stall.
4. Crank the engine for an additional 10 seconds.
Fuel System Pressure Test
Step Action Value(s) Yes No




1




1. Relieve the fuel system pressure.
2. Install a fuel pressure gauge.
3. Turn the ignition ON.
Is the fuel pressure around the values specified and
holding steady?



380 kPa
(55 psi)



System OK



Go to Step 2




2




1. Relieve the fuel system pressure.
2. Install a fuel pressure gauge.
3. Turn the ignition ON.
Is the fuel pressure around the values specified but
not holding steady?


380 kPa
(55 psi)



Go to Step 13



Go to Step 3

3

Inspect the fuel lines for a leak.
Is the problem found?
–

Go to Step 4

Go to Step 5




4




1. Replace the fuel line(s) as needed.
2. Install a fuel pressure gauge.
3. Turn the ignition ON.
Is the fuel pressure around the values specified and
holding steady?


380 kPa
(55 psi)



System OK




–




5




1. Remove the fuel pump assembly.
2. With the fuel pump under pressure, inspect the
fuel pump coupling hoses for leaking.
Is the problem found?



–



Go to Step 6



Go to Step 7





6





1. Tighten or replace the fuel pump coupling hoses
as needed.
2. Install a fuel pressure gauge.
3. Turn the ignition ON.
Is the fuel pressure around the values specified and
holding steady?




380 kPa
(55 psi)




System OK




Go to Step 8

7


With the fuel system under pressure, inspect the fuel
return outlet for leaking.
Is the problem found?
–

Go to Step 8

Go to Step 9

ENGINE CONTROLS 1F–35
DAEWOO M-150 BL2
Fuel System Pressure Test (Cont’d)
Step Action Value(s) Yes No




8




1. Replace the fuel pressure regulator.
2. Install a fuel pressure gauge.
3. Turn the ignition ON.
Is the fuel pressure around the values specified and
holding steady?



380 kPa
(55 psi)



System OK




–



9



With the fuel system under pressure, inspect the fuel
return inlet for leaking.
Is the problem found?


–


Go to Step 10


Go to Step 11




10




1. Replace the fuel pump assembly.
2. Install a fuel pressure gauge.
3. Turn the ignition ON.
Is the fuel pressure around the values specified and
holding steady?



380 kPa
(55 psi)



System OK




–




11




1. Remove the fuel rail and the fuel injectors as an
assembly.
2. With the fuel system under pressure, inspect all
of the fuel injectors for leaking.
Is the problem found?



–



Go to Step 12




–




12




1. Replace the leaking fuel injector(s).
2. Install a fuel pressure gauge.
3. Turn the ignition ON.
Is the fuel pressure around the values specified and
holding steady?


380 kPa
(55 psi)



System OK




–





13





1. Replace the fuel pressure regulator.
2. Start the engine.
3. Allow the engine to idle.
Is the fuel pressure around the values specified and
holding steady?




380 kPa
(55 psi)




System OK





–

1F–36 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F040
FUEL PUMP RELAY CIRCUIT CHECK
Circuit Description
When the ignition switch is turned ON, the Engine Con-
trol Module (ECM) will supply battery voltage to activate
the fuel pump relay and run the in-tank fuel pump. The
fuel pump will operate as long as the engine is cranking
or running and the ECM is receiving ignition reference
pulses.If there are no reference pulses, the ECM will shut off
the fuel pump within 2 seconds after the ignition switch
is turned ON.
Diagnostic Aids
An intermittent problem may be caused by a poor con-
nection, rubbed through wire insulation, or a broken wire
inside the insulation.
Fuel Pump Relay Circuit Check
StepActionValue(s)YesNo
1
1. Turn the ignition OFF for 10 seconds.
2. Turn the ignition ON.
3. Listen for in-tank fuel pump operation.
Does the fuel pump operate for the time specified?
2 secSystem OKGo to Step 2
2
1. Turn the ignition OFF.
2. Connect battery positive to fuel pump test
connect.
3. Listen for in-tank fuel pump operation.
Does the fuel pump operate?
–
Go to Step 4Go to Step 3

ENGINE CONTROLS 1F–37
DAEWOO M-150 BL2
Fuel Pump Relay Circuit Check (Cont’d)
StepActionValue(s)YesNo
3
1. Check for an open circuit between fuel pump test
connector and ground G401, and repair as
needed.
2. Check for the fuel cut-off switch and reset or
replace the fuel cut off switch.
Is the repair complete?
–
System OKGo to Step 4
4
1. Turn the ignition OFF.
2. Disconnect the fuel pump relay.
3. Connect a test light between the fuel pump relay
connector terminal 66 and battery positive.
4. Turn the ignition ON.
Is the test light on?
–
Go to Step 6Go to Step 5
5
Check for an open circuit between terminal 66 of fuel
pump relay and battery positive and repair as
needed.
Is the repair complete?
–
System OK
–
6
1. Turn the ignition OFF.
2. Connect a test light between the fuel pump relay
connector terminal 85 and ground.
3. Turn the ignition ON.
Is the test light on?
2 secGo to Step 8Go to Step 7
7
Check for an open circuit between terminal 85 of fuel
pump relay and terminal 10 of ECM, and repair as
needed.
Is the repair complete?
–
System OK
–
8
1. Turn the ignition OFF.
2. Connect a test light between the fuel pump relay
connector terminal 30 and ground.
Is the test light on?
–
Go to Step 10Go to Step 9
9
1. Check the fuse EF19, if blown, repair short circuit
between fuel pump relay 30 terminal.
2. Replace the fuse as needed.
3. Repair an open circuit as needed.
Is the repair complete?
–
System OK
–
10
1. Turn the ignition OFF.
2. Measure the resistance between following
terminals:

Terminal 87 of fuel pump relay and terminal 1
of the fuel cut-off switch(or terminal 1 of
connector C201).
Does the resistance within the value specified.
0 ΩGo to Step 12Go to Step 11
11Repair an open circuit as needed.
Is the repair complete?–System OK–
12Replace the fuel pump relay.
Is the repair complete?–System OKGo to Step 13
13Replace the ECM.
Is the repair complete?–System OK–

1F–38 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F050
MAIN RELAY CIRCUIT CHECK
Circuit Description
When the ignition is turned On or to the START position,
the main relay is energized. The main relay then supply
voltage to the engine fuse block fuse EF25 and EF26.
The Electronic Ignition (EI) system ignition coil is sup-
plied voltage through the engine fuse block fuse EF26.
The fuel injectors are supplied voltage through the en-
gine fuse block fuse EF25.Diagnostic Aids

An intermittent problem may be caused by a poor
connection, rubbed through wire insulation, or a bro-
ken wire inside the insulation.

A fault main relay will cause a no start condition.
There will be no voltage supplied to the EI system
ignition coil, or the fuel injectors. Without voltage sup-
plied to these components, they will not operate.

ENGINE CONTROLS 1F–39
DAEWOO M-150 BL2
Main Relay Circuit Check
StepActionValue(s)YesNo
1
1. Turn the ignition OFF.
2. Disconnect the engine fuse block fuse EF26.
3. Turn the ignition ON.
4. With a test light connected to the ground, probe
the fuse terminals nearest the main relay for fuse
EF19.
Is the light on at both terminal?
–
System OKGo to Step 2
2Is the light on at only one terminal?–Go to Step 3Go to Step 4
3
Repair the open in the wiring between the main relay
connector terminal 30 and the fuse EF19 as needed.
Is the repair complete?
–
System OK
–
4
1. Turn the ignition OFF.
2. Remove the main relay.
3. Turn the ignition ON.
4. With a test light connected to the ground, probe
the main relay terminals 85 and 30.
Is the light on at both terminals.
–
Go to Step 8Go to Step 5
5
1. Turn the ignition OFF.
2. Check engine fuse block fuse EF19.
Is one or both fuse blown?
–
Go to Step 6Go to Step 7
6
1. Repair short circuit between terminal 87 of main
relay and heated oxygen sensor
2. Replace fuse EF19.
Is the repair complete?
–
System OK
–
7
Repair open circuit between terminal 30 of main
relay and fuse EF19.
Is the repair complete?
–
System OKGo to Step 8
8
1. Turn the ignition OFF.
2. Measure the resistance between following
terminals.

Terminal 86 of main relay and ground.

Terminal 87 of main relay and ground.
Is the resistance within the specified value
0 ΩGo to Step 10Go to Step 9
9Repair open circuit.
Is the repair complete?–System OK–
10Replace the main relay.
Is the repair complete?–System OK–

1F–40 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F060
MANIFOLD ABSOLUTE PRESSURE CHECK
Circuit Description
The Manifold Absolute Pressure (MAP) sensor measure
the changes in the intake manifold pressure which result
from engine load (intake manifold vacuum) and rpm
changes. The MAP sensor converts these changes into
voltage output. The Engine Control Module (ECM) send
a 5-volt reference voltage to the MAP sensor. As the in-
take manifold pressure changes, the output voltage ofMAP sensor also changes. A low voltage (high vacuum)
output of 1 to 1.5 volts is present at idle. A high voltage
(low vacuum) output of 4.5 to 5.0 volts is present at wide
open throttle. The MAP sensor is also used under cer-
tain conditions to measure barometric attitude changes.
The ECM uses the MAP sensor for the delivery and igni-
tion timing changes.

ENGINE CONTROLS 1F–41
DAEWOO M-150 BL2
Manifold Absolute Pressure Check
StepActionValue(s)YesNo
1
1. Turn the ignition OFF.
2. Connect a scan tool to the Data Link Connector
(DLC).
3. Turn the ignition ON.
4. Compare the Manifold Absolute Pressure (MAP)
sensor voltage reading from scanner with that
from known good vehicle.
Is the difference in the two voltage reading less than
the value specified?
0.4 VGo to Step 2Go to Step 5
2
1. Turn the ignition OFF.
2. Connect a scan tool to the DLC.
3. Disconnect the MAP sensor vacuum line.
4. Connect a hand vacuum pump to the Map sensor.
5. Turn the ignition ON.
6. Note the MAP sensor voltage.
7. Apply 34kPa (10 in. Hg) of vacuum to the Map
sensor and note the voltage change.
Is the difference in voltage readings more than the
value specified?
1.5 VSystem OKGo to Step 3
3Inspect the MAP sensor connector terminals.
Is the problem found.–Go to Step 4Go to Step 5
4
Repair the MAP sensor connector terminals as
needed.
Is the repair complete?
–
System OK
–
5Replace the MAP sensor.
Is the repair complete?–System OK–

1F–42 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F070
IDLE AIR CONTROL SYSTEM CHECK
Circuit Description
The Engine Control Module (ECM) controls the engine
idle speed with the Idle Air Control (IAC) valve. To in-
crease the idle speed, the ECM pulls the IAC pintle
away from its seat, allowing more air to pass by the
throttle body. To decrease the idle speed, it extends the
IAC valve pintle toward its seat, reducing bypass air
flow. A scan tool will read the ECM commands to the
IAC valve in counts. The higher counts indicate more air
bypass (higher idle). The lower counts indicate less air is
allowed to bypass (lower idle).
Diagnostic Aids
If the idle is too high, stop the engine. Fully extend the
Idle Air Control (IAC) valve with a IAC driver. Start the
engine. If the idle speed is above 950 rpm, locate and
repair the vacuum leak. Also, check for a binding throttle
plate or throttle linkage or an incorrect base idle setting.
Idle Air Control Valve Reset Procedure
Whenever the battery cable or the Engine Control Mod-
ule (ECM) connector or the ECM fuse EF6 is discon-nected or replaced, the following idle learn procedure
must be performed:
1. Turn the ignition ON for 5 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON for 5 seconds.
4. Start the engine in park/neutral.
5. Allow the engine to run until the engine coolant is
above 85C (185F ).
6. Turn the A/C ON for 10 seconds, if equipped.
7. Turn the A/C OFF for 10 seconds, if equipped.
8. If the vehicle is equipped with an automatic trans-
axle, apply the parking brake. While pressing the
brake pedal, place the transaxle in D (drive).
9. Turn the A/C ON for 10 seconds, if equipped.
10. Turn the A/C OFF for 10 seconds, if equipped.
11. Turn the ignition OFF. The idle learn procedure is
complete.