sensor DAEWOO MATIZ 2003 Service Repair Manual

1F–274 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F340
DIAGNOSTIC TROUBLE CODE (DTC) – P0656 FUEL LEVEL GAUGE CIRCUIT
FAULT
Circuit Description
The engine control module(ECM) uses the fuel level in-
put from the Fuel Level Sensor to calculate expected va-
por pressures within the fuel system. Vapor pressure
vary as the fuel level changes. Vapor pressure is critical
in determining if the evaporative emission (EVAP) sys-
tem is operating properly. Fuel Level is also used to de-
termine if the Fuel level is too high or too low to be able
to accurately detect EVAP system faults. This Diagnos-
tic Trouble Code(DTC) detects a stuck fuel level sender.
Conditions for Setting the DTC

Fuel Level Sensor voltage is higher than 4.8V.

Fuel Level Sensor circuit high voltage.
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
Inspect harness connectors for backed-out terminal, im-
proper mating, broken locks, improperly formed or dam-
aged terminals, and poor terminal-to-wire connection.
Inspect the wiring harness for damage.
A stuck Fuel Level Sensor may cause the DTC to set. If
DTC P0656 cannot be duplicated, the information in-
cluded in the Freeze Frame data can be useful in deter-
mining vehicle operating conditions when the DTC was
first set.
Resistance check for the Fuel Level Sensor.

Empty = 100 ohms or over.

Half full = about 32.5 ohms.

Full = 10 ohms or less.

ENGINE CONTROLS 1F–281
DAEWOO M-150 BL2
INTERMITTENT
Definition: The problem may or may not illuminate the
Malfunction Indicator Lamp (MIL) or store a Diagnostic
Trouble Code (DTC).
Important: Do not use the Diagnostic Trouble Code
(DTC) tables for intermittent problems. A fault must bepresent in order to locate the problem. If a fault is inter-
mittent, use of Diagnostic Trouble Code tables may re-
sult in the replacement of good parts.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Perform a careful inspection of any suspect
circuits.
2. Inspect for poor mating of the connector halves,
or terminals not fully seated into the connector
body.
3. Inspect for improperly formed or damaged
terminals.
4. Inspect for poor terminal-to-wire connections.
This requires removing the terminal from the
connector body to inspect it.
Are any problems present?
–
Go to Step 3Go to Step 4
3Repair the electrical connections as needed.
Is the repair complete?–System OK–
4
Road test the vehicle with a voltmeter connected to
a suspected circuit or a scan tool connected to the
Data Link Connector (DLC).
Did the voltmeter or the scan tool indicate an
abnormal voltage or scan reading?
–
Go to Step 5Go to Step 6
5
Replace the sensor in the affected circuit, if a
Diagnostic Trouble Code (DTC) was stored for this
circuit (except for the DTCs P0171 and P0172).
Is the repair complete?
–
System OK
–
6Does an intermittent Malfunction Indicator Lamp
(MIL) or DTC occur?–Go to Step 7Go to Step 8
7
1. Check for a faulty relay, Engine Control Module
(ECM) driven solenoid, or switch.
2. Check for improper installation of electrical
devices, such as lights, two-way radios, electric
motors, etc.
3. Inspect the ignition control wires for proper
routing (away from ignition wires, ignition system
components, and the generator).
4. Check for a short-to-ground in the MIL circuit or
the DLC “test” terminal.
5. Inspect the ECM ground connections.
6. Correct or repair the affected circuits as needed.
Is the repair complete?
–
System OK
–
8
1. Check for a loss of DTC memory.
2. Disconnect the throttle position (TP) sensor.
3. Run the engine at idle until the MIL comes on.
4. Turn the ignition OFF.
Is DTC P0122 stored in memory?
–
Go to Step 10Go to Step 9

1F–282 ENGINE CONTROLS
DAEWOO M-150 BL2
Intermittent (Cont’d)
StepActionValue(s)YesNo
9
1. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?
–
System OK
–
10Does the vehicle stall while driving?–Go to Step 11Go to Step 12
11
Monitor the oxygen sensor and the injector base
pulse width with the scan tool.
Does the scan tool display a steady low voltage
(about 0 millivolts) for the oxygen sensor with the
control module commanding an injector base pulse
width of the value specified?
8 msGo to Step 9Go to Step 12
12
1. Check for an open diode across the A/C clutch
and for other open diodes.
2. Repair or replace any components as needed.
Is the repair complete?
–
System OK
–

ENGINE CONTROLS 1F–283
DAEWOO M-150 BL2
HARD START
Definition: The engine cranks OK, but does not start for
a long time. The engine eventually runs or may start and
immediately die.Important: Ensure that the driver is using the correct
starting procedure. Before diagnosing, check service
bulletins for updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Connect the scan tool to the Data Link Connector
(DLC).
2. Check the Engine Coolant Temperature (ECT)
sensor and the Intake Air Temperature (IAT)
sensor using the scan tool.
3. Compare the coolant temperature and the IAT
with the ambient temperature when the engine is
cold.
Do the ECT and the IAT readings differ from the
ambient temperature by more than the value
specified?
3
C (5
F)Go to Step 3Go to Step 4
3
1. Measure the resistance of the ECT sensor and
the IAT sensor.
2. Compare the resistance value to specifications
using the Temperature Vs. Resistance tables for
DTCs P0118 and P0113.
3. If the resistance is not the same, replace the
faulty sensor.
Is the repair complete?
–
System OK
–
4
1. Check for a sticking throttle shaft or a binding
linkage that may cause a high Throttle Position
(TP) sensor voltage. Repair or replace as
needed.
2. Check the TP sensor voltage reading with the
throttle closed.
Does the voltage measure within the value
specified?
0.4–0.8 VGo to Step 5Go to Step 26
5
1. Check the Manifold Absolute Pressure (MAP)
sensor response and accuracy.
2. Replace the MAP sensor as needed.
Is the repair complete?
–
System OKGo to Step 6
6
Check the fuel pump operation.
Does the fuel pump operate for the specified time
when the ignition switch is turned ON?
2 secGo to Step 7
Go to “Fuel
Pump Relay
Circuit Check”
7Check the fuel system pressure.
Is the fuel pressure within the specifications?380 kPa
(55 psi)
Go to Step 8Go to Step 27
8Check for water contamination in the fuel.
Is fuel contaminated?–Go to Step 9Go to Step 10
9Replace the contaminated fuel.
Is the repair complete?–System OK–

1F–284 ENGINE CONTROLS
DAEWOO M-150 BL2
Hard Start (Cont’d)
StepActionValue(s)YesNo
10
1. Check the fuel injector driver circuit.
2. Disconnect all of the fuel injector harness
connectors at the fuel injectors.
3. Connect an injector test light between the
harness terminals of each fuel injector connector.
4. Note the test light while cranking the engine.
Does the test light blink at all connectors?
–
Go to Step 13Go to Step 11
11
Check the fuel injector driver wiring harness, the
connectors, and the connector terminals for the
proper connections.
Is the problem found?
–
Go to Step 12Go to Step 28
12
Repair the wiring harness, the connector, or the
connector terminal as needed.
Is the repair complete?
–
System OK
–
13
Measure the resistance of each fuel injector.
Is the fuel injector resistance within the value
specified at 20
C (68
F)
Note: The resistance will increase slightly at higher
temperatures)?
11.6–12.4 ΩGo to Step 15Go to Step 14
14
Replace any fuel injector with a resistance that is out
of specifications.
Is the repair complete?
–
System OK
–
15Perform an injector diagnosis.
Is the problem found?–Go to Step 16Go to Step 17
16
Replace any restricted or leaking fuel injectors as
needed.
Is the repair complete?
–
System OK
–
17
1. Check for the proper ignition voltage output for
each cylinder with a spark tester.
2. Inspect the spark plugs for cracks, wear, improper
gap, burned electrodes, or heavy deposits.
3. Inspect the ignition wires for short conditions.
4. Inspect all of the ignition grounds for loose
connections.
5. Inspect the Engine Control Module (ECM) for the
proper operation.
Is the problem found?
–
Go to Step 18Go to Step 19
18Correct or replace any faulty ignition components.
Is the repair complete?–System OK–
19Does the engine misfire or cut out under load or at
idle?–Go to “Ignition
System Check”
Go to Step 20
20Does the engine start, but then immediately stall?–Go to Step 21Go to Step 23
21
1. Remove the Crankshaft Position (CKP) sensor.
2. Inspect for faulty connections and repair as
needed.
Is the problem found?
–
Go to Step 22Go to Step 25
22Repair the faulty connections as needed.
Is the repair complete?–System OK–

ENGINE CONTROLS 1F–285
DAEWOO M-150 BL2
Hard Start (Cont’d)
StepActionValue(s)YesNo
23
1. Check for the proper valve timing.
2. Check the cylinder compression.
3. Inspect the pushrods, the rocker arms, the valve
springs, and the camshaft lobes for excessive
wear.
4. Inspect the intake manifold and the exhaust
manifold passages for casting flash.
Is the problem found?
–
Go to Step 24Go to Step 25
24Repair or replace any components as needed.
Is the repair complete?–System OK–
25
Check the idle air control valve operation. Repair or
replace components as needed.
Is the repair complete?
–
System OK
–
26
Check the throttle position sensor circuit for proper
operation. Repair or replace components as needed.
Is the repair complete?
–
System OK
–
27Repair the fuel system as needed.
Is the repair complete?–System OK–
28
1. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?
–
System OK
–

1F–286 ENGINE CONTROLS
DAEWOO M-150 BL2
SURGES OR CHUGGLES
Definition: Engine power variation under steady throttle
or cruise. Feels like the vehicle speeds up and slows
down with no change in the accelerator pedal position.Important: Make sure the driver understands A/C com-
pressor operation as described in the owner’s manual.
The speedometer reading and the speed reading on the
scan tool should be equal.
Before diagnosing the symptom, check service bulletins
for updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
Connect the scan tool to the Data Link Connector
(DLC).
Does the oxygen sensor (O2S) respond quickly to
different throttle positions?
–
Go to Step 4Go to Step 3
3
1. Check the O2S for silicone or other contaminants
from fuel or use of improper Room Temperature
Vulcanizing (RTV) sealant.
2. Replace the contaminated O2S.
Is the repair complete?
–
System OK
–
4
1. Drive the vehicle at the speed of the complaint.
2. Monitor the long term fuel trim reading using the
scan tool.
Is the long term fuel trim reading within the value
specified?
–20–25%Go to Step 7Go to Step 5
5
Is the long term fuel trim reading below the value
specified?
–20%
Go to
“Diagnostic Aids
for DTC P0172”
Go to Step 6
6
Is the long term fuel trim reading above the value
specified?
25%
Go to
“Diagnostic Aids
for DTC P0171”
–
7
Check the fuel system pressure while the condition
exists.
Is the fuel system pressure within specifications?
380 kPa
(55 psi)
Go to Step 8Go to Step 17
8Check the in-line fuel filter.
Is the filter dirty or plugged?–Go to Step 18Go to Step 9
9Perform an injector diagnosis.
Did the injector diagnosis pinpoint the problem?–Go to Step 19Go to Step 10
10
1. Check for proper ignition voltage output using a
spark tester.
2. Inspect the spark plugs for cracks, wear, improper
gap, burned electrodes, or heavy deposits.
Is the problem found?
–
Go to Step 11Go to Step 12
11
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–
12
1. Inspect the ECM grounds for being clean, tight,
and in their proper locations.
2. Inspect the vacuum lines for kinks or leaks.
Is the problem found?
–
Go to Step 13Go to Step 14

1F–290 ENGINE CONTROLS
DAEWOO M-150 BL2
DETONATION/SPARK KNOCK
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Fill the fuel tank with a known good grade of
gasoline that has the octane rating of the value
specified.
2. Reevaluate the vehicle’s performance.
Does the detonation problem still exist?
91 octaneGo to Step 3System OK
3
1. Inspect for low engine coolant level.
2. Check for restricted airflow to the radiator or
restricted coolant flow.
3. Check for a faulty thermostat.
4. Check for an incorrect coolant solution.
Is the problem found?
–
Go to Step 4Go to Step 5
4
Repair or replace any cooling system components
as needed.
Is the repair complete?
–
System OK
–
5
1. Check the engine coolant temperature using the
scan tool.
2. Replace the Engine Coolant Temperature (ECT)
sensor if the resistance is not within specifications
as listed in the Diagnostic Aids for diagnostic
trouble code P0118.
Is the problem found?
–
Go to Step 6Go to Step 7
6
Replace the ECT sensor or repair the circuit as
needed.
Is the repair complete?
–
System OK
–
7
1. Check the ignition system output with a spark
tester.
2. Inspect the spark plugs for the proper heat range
and gap.
3. Check for the proper operation of the ignition
controls.
Is the ignition system operating properly?
–
Go to Step 9Go to Step 8
8
Repair or replace the ignition system components as
needed.
Is the repair complete?
–
System Ok
–
9
1. Connect the scan tool to the Data Link Connector
(DLC).
2. Road test the vehicle at the speed of the
complaint.
3. Monitor the long term fuel trim reading from the
scanner data stream.
Is the long term fuel trim reading above the value
specified?
25%
Go to
“Diagnostic Aids
for DTC P0171”
Go to Step 10
10Check the fuel system pressure.
Is the problem found?380 kPa
(55 psi)
Go to Step 11Go to Step 12
11
Repair or replace the fuel system components as
needed.
Is the repair complete?
–
System OK
–

1F–292 ENGINE CONTROLS
DAEWOO M-150 BL2
HESITATION, SAG, STUMBLE
Definition: Momentary lack of response as the accelera-
tor is pushed down. This can occur at any vehicle speed.
It is usually the most severe when first trying to make the
vehicle move, as from a stop. Hesitation, sag, or
stumble may cause the engine to stall if severe enough.Important: Before diagnosing this condition, check ser-
vice bulletins for PROM updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Check the fuel system pressure. If the pressure is
not within the value specified, service the fuel
system as needed.
2. Inspect the Throttle Position (TP) sensor for
binding or sticking. The TP sensor voltage should
increase at a steady rate as the throttle is moved
toward Wide Open Throttle (WOT).
Is the problem found?
380 kPa
(55 psi)
Go to Step 3Go to Step 4
3Repair or replace any components as needed.
Is the repair complete?–System OK–
4
1. Check the Manifold Absolute Pressure (MAP)
sensor response and accuracy.
2. Inspect the fuel for water contamination.
3. Check the Evaporative Emission (EVAP) Canister
Purge System for proper operation.
Is the problem found?
–
Go to Step 5Go to Step 6
5Repair or replace any components as needed.
Is the repair complete?–System OK–
6
1. Disconnect all of the fuel injector harness
connectors.
2. Connect an injector test light between the
harness terminals of each fuel injector.
3. Note the test light while cranking the engine.
Does the test light blink on all connectors?
–
Go to Step 8Go to Step 7
7
1. Repair or replace the faulty fuel injector drive
harness, the connector, or the connector terminal.
2. If the connections and the harnesses are good,
replace the Engine Control Module (ECM).
Is the repair complete?
–
System OK
–
8
Measure the resistance of each fuel injector.
Is the fuel injector resistance within the value
specified (the resistance will increase slightly at
higher temperatures)?
11.6–12.4 ΩGo to Step 10Go to Step 9
9
Replace any of the fuel injectors with a resistance
that is out of specifications.
Is the repair complete?
–
System OK
–
10Perform an injector diagnosis.
Is the problem found?–Go to Step 11Go to Step 12
11Replace any restricted or leaking fuel injectors.
Is the repair complete?–System OK–
12
Check the fuel system pressure after a cold start or
during moderate or full throttle acceleration.
Is the fuel pressure within specifications?
380 kPa
(55 psi)
Go to Step 14Go to Step 13

ENGINE CONTROLS 1F–297
DAEWOO M-150 BL2
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING
Definition: The engine runs unevenly at idle. If the condi-
tion is bad enough, the vehicle may shake. Also, the idle
varies in rpm (called “hunting”). Either condition may be
severe enough to cause stalling. The engine idles at in-
correct idle speed.Important: Before diagnosing the symptom, check ser-
vice bulletins for updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Connect the scan tool to the Data Link Connector
(DLC).
2. Monitor the oxygen sensor (O2S) reading at
different throttle positions.
Does the O2S change quickly from rich to lean at
the different throttle positions?
–
Go to Step 5Go to Step 3
3
Check the O2S for contamination from fuel or
improper use of room temperature vulcanizing
sealant.
Is the O2S contaminated?
–
Go to Step 4Go to Step 5
4Replace the contaminated O2S as needed.
Is the repair complete?–System OK–
5
1. Check for a sticking throttle shaft or binding
throttle linkage that may cause incorrect Throttle
Position (TP) sensor voltage.
2. Check the TP sensor voltage reading with the
throttle closed.
Is the TP sensor voltage within the value specified?
0.4–0.8 VGo to Step 6
Go to
“Diagnostic
Aids for DTC
P0123”
6
1. Check the Engine Coolant Temperature (ECT)
sensor voltage reading using the scan tool.
2. Compare the ECT sensor reading with the
ambient temperature when the engine is cold.
Does the ECT sensor temperature reading differ
from the ambient temperature by more than the
value specified?
3
C (5
F)Go to Step 7Go to Step 9
7
Check for high resistance in the ECT sensor circuit
or the sensor itself.
Is the problem found?
–
Go to Step 8Go to Step 9
8
Replace the ECT sensor or repair the circuit as
needed.
Is the repair complete?
–
System OK
–
9
Check the Manifold Absolute Pressure (MAP)
sensor for response and accuracy.
Is the problem found?
–
Go to Step 10Go to Step 11
10
Replace the MAP sensor or repair the MAP sensor
circuit as needed.
Is the repair complete?
–
System OK
–
11
1. Road test the vehicle at the speed of the
complaint.
2. Monitor the long term fuel trim reading using the
scan tool.
Is the long term fuel trim reading within the value
specified?
–20–25%Go to Step 14Go to Step 12