TRANSAXLE DAEWOO MATIZ 2003 Service User Guide

1F–242 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F280
DIAGNOSTIC TROUBLE CODE (DTC) – P0501 VEHICLE SPEED NO SIGNAL
(M/T ONLY)
Circuit Description
Vehicle speed information is provided to the engine con-
trol module (ECM) by the voltage speed sensor (VSS) is
a permanent magnet generator that is mounted in the
transaxle and produces a pulsing voltage whenever ve-
hicle speed is over 3 mph (5km/h). The A/C voltage level
and the number of pulses increase with vehicle speed.
The ECM converts the pulsing voltage into mph (km/h)
and than supplies the necessary signal to the instrument
panel for speedometer / odometer operation and to the
cruise control module and multi-function alarm module
operation. The Diagnostic Trouble Code (DTC) will de-
tect if vehicle speed is reasonable according to engine
rpm and load.
Conditions for Setting the DTC

Vehicle speed is not change at least 10 seconds.

Engine speed is greater than 2,100rpm.

MAF is greater than 152mg/tdc.
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.

Using the scan tool can clear DTC(s).
Diagnostic Aids
An Intermittent problem may be caused by a poor con-
nection, rubbed through wire insulation, or wire that is
broken inside the insulation.
VSS signal circuit should be thoroughly checked for the
following conditions

Backed-out terminals

Improper mating

Broken locks

Improperly formed

Damaged terminals

Poor terminals to wire connection

Physical damage to the wiring harness
Ensure the VSS is correctly torqued to the trnasaxle
housing.
Refer to “intermittents” in this Section.

1F–262 ENGINE CONTROLS
DAEWOO M-150 BL2
DIAGNOSTIC TROUBLE CODE (DTC) – P0601 ENGINE CONTROL MODULE
CHECKSUM ERROR
Circuit Description
The engine control module (ECM) is the control center
of the fuel injection system. It constantly looks at the in-
formation from various sensors, and controls the sys-
tems that after vehicle performance. The ECM also
performs the diagnostic function of the system. It can
recognize operational problems, alert the driver through
the Malfunction Indicator Lamp (MIL), and store a Diag-
nostic Trouble Code (DTC) or DTCs which identify the
problem areas to aid the technician in making repairs.
An electrically erasable programmable read only
memory (EEPROM) is used to house the program infor-
mation and the calibrations required for engine, trans-
axle, transaxle diagnostics operation. The ECM uses a
value called a checksum for error detection of the soft-
ware. The checksum is a value that is equal to all the
numbers in the software added together. The ECM adds
all the values in the software and if that value does notequal the checksum value, a checksum error is indi-
cated.
Conditions for Setting the DTC

The ECM detects more than 3 incorrect checksum.
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.
DTC P0601– Engine Control Module Checksum Error
StepActionValue(s)YesNo
1
Perform an On-Board Diagnostic (EOBD) System
Check.
Is the system check complete?
–
Go to Step 2
Go to
“On-Board
Diagnostic
System Check”
2Replace the engine control module(ECM).
Is the replacement complete?–Go to Step 3–
3
1. Using the scan tool, clear the DTCs.
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for
setting this DTC ad specified in the supporting
text.
Does the scan tool indicate that this diagnostic has
run and passed?
–
Go to Step 4Go to Step 2
4
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–263
DAEWOO M-150 BL2
DIAGNOSTIC TROUBLE CODE (DTC) – P0604 ENGINE CONTROL MODULE
INTERNAL/EXTERNAL RAM ERROR
Circuit Description
The engine control module (ECM) is the control center
of the fuel injection system. It constantly looks at the in-
formation from various sensors, and controls the sys-
tems that after vehicle performance. The ECM also
performs the diagnostic function of the system. It can
recognize operational problems, alert the driver through
the Malfunction Indicator Lamp (MIL), and store a Diag-
nostic Trouble Code (DTC) or DTCs which identify the
problem areas to aid the technician in making repairs.
An electrically erasable programmable read only
memory (EEPROM) is used to house the program infor-
mation and the calibrations required for engine, trans-
axle, transaxle diagnostics operation. The ECM uses a
value called a checksum for error detection of the soft-
ware. The checksum is a value that is equal to all the
numbers in the software added together. The ECM adds
all the values in the software and if that value does not
equal the checksum value, a checksum error is indi-
cated.Conditions for Setting the DTC

The ECM detects more than 3 incorrect checksum.
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.

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.
DTC P0604 – Engine Control Module RAM Error
StepActionValue(s)YesNo
1
Perform an On-Board Diagnostic (EOBD) System
Check.
Is the system check complete?
–
Go to Step 2
Go to
“On-Board
Diagnostic
System Check”
2Replace the engine control module(ECM).
Is the replacement complete?–Go to Step 3–
3
1. Using the scan tool, clear the DTCs.
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for
setting this DTC ad specified in the supporting
text.
Does the scan tool indicate that this diagnostic has
run and passed?
–
Go to Step 4Go to Step 2
4
Check if any additional DTCs are set.
Are any DTCs displayed that have not been
diagnosed?
–
Go to
applicable DTC
table
System OK

1F–264 ENGINE CONTROLS
DAEWOO M-150 BL2
DIAGNOSTIC TROUBLE CODE (DTC) – P0605 ENGINE CONTROL MODULE
NMVY WRITE ERROR
Circuit Description
The engine control module (ECM) is the control center of
the fuel injection system. It constantly looks at the infor-
mation from various sensors, and controls the systems
that after vehicle performance. The ECM also performs
the diagnostic function of the system. It can recognize op-
erational problems, alert the driver through the Malfunc-
tion Indicator Lamp (MIL), and store a Diagnostic Trouble
Code (DTC) or DTCs which identify the problem areas to
aid the technician in making repairs. An electrically eras-
able programmable read only memory (EEPROM) is
used to house the program information and the calibra-
tions required for engine, transaxle, transaxle diagnos-
tics operation. The ECM uses a value called a checksum
for error detection of the software. The checksum is a val-
ue that is equal to all the numbers in the software added
together. The ECM adds all the values in the software
and if that value does not equal the checksum value, a
checksum error is indicated.Conditions for Setting the DTC

The ECM detects more than 3 incorrect checksum.
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.

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.
DTC P0605 Engine Control Module NMVY Write Error
StepActionValue(s)YesNo
1
Perform an On-Board Diagnostic (EOBD) System
Check.
Is the system check complete?
–
Go to Step 2
Go to
“On-Board
Diagnostic
System Check”
2Replace the engine control module(ECM).
Is the replacement complete?–Go to Step 3–
3
1. Using the scan tool, clear the DTCs.
2. Start the engine and idle at normal operating
temperature.
3. Operate the vehicle within the conditions for
setting this DTC ad specified in the supporting
text.
Does the scan tool indicate that this diagnostic has
run and passed?
–
Go to Step 4Go to Step 2
4
Check if any additional DTCs are set.
Are any DTCs displayed that have not been
diagnosed?
–
Go to
applicable DTC
table
System OK

1F–288 ENGINE CONTROLS
DAEWOO M-150 BL2
LACK OF POWER, SLUGGISHNESS, OR SPONGINESS
Definition: The engine delivers less than expected pow-
er. There is little or no increase in speed when the accel-
erator pedal is partially applied.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Verify the customer’s complaint.
2. Compare the performance of the customer’s
vehicle with a similar unit.
Does the problem exist?
–
Go to Step 3System OK
3
1. Inspect the air filter for excessive contamination.
2. Replace the air filter as needed.
3. Check the transaxle shift pattern and down shift
operation.
Does the transaxle operate properly?
–
Go to Step 4Go to Step 5
4Check the fuel system pressure.
Is the fuel system pressure within specifications?380 kPa
(55 psi)
Go to Step 7Go to Step 6
5Repair the transaxle as needed.
Is the repair complete?–System OK–
6Repair the fuel system as needed.
Is the repair complete?–System OK–
7Check for a restricted fuel filter or contaminated fuel.
Is the problem found?–Go to Step 8Go to Step 9
8Repair or replace any components as needed.
Is the repair complete?–System OK–
9
1. Check the ignition system output for all of the
cylinders using a spark tester.
2. Check for proper ignition control operation.
Is the ignition system operating properly?
–
Go to Step 10Go to Step 11
10
1. With the engine at normal operating temperature,
connect a vacuum gauge to a vacuum port on the
intake manifold.
2. Operate the engine at 1000 rpm.
3. Record the vacuum reading.
4. Increase the engine speed to 2500 rpm.
5. Note the vacuum reading at a steady 2500 rpm.
Does the vacuum decrease more than the value
specified?
10 kPa
(3 in Hg)
Go to Step 12Go to Step 15
11
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–
12
Inspect the exhaust system for restrictions and
damaged or collapsed pipes.
Is the problem found?
–
Go to Step 13Go to Step 14
13Repair or replace any components as needed.
Is the repair complete?–System OK–
14
1. Check the cylinder compression and valve timing.
2. Inspect the camshaft for excessive wear.
Is the problem found?
–
Go to Step 15Go to Step 16

ENGINE CONTROLS 1F–291
DAEWOO M-150 BL2
Detonation/Spark Knock (Cont’d)
StepActionValue(s)YesNo
12
1. Inspect for carbon buildup inside the engine.
2. Remove the carbon with a top engine cleaner.
Follow the instructions supplied with the product.
3. Check the basic engine parts such as the
camshaft, the cylinder head, the pistons, etc. for
excessive wear.
4. Replace any excessively worn parts.
Is the procedure complete?
–
Go to Step 13
–
13
1. Check the exhaust gas recirculation valve for
proper operation.
2. Check the air intake system for proper operation.
3. Check the torque converter clutch operation and
transaxle shift points.
4. Check the service bulletins for Programmable
Read Only Memory (PROM) updates.
5. Check the cylinder compression.
6. Repair or replace any faulty components.
Are all checks and repairs complete?
–
System OK
–

1F–296 ENGINE CONTROLS
DAEWOO M-150 BL2
POOR FUEL ECONOMY
Definition: Fuel economy, as measured by an actual
road test, is noticeably lower than expected. Also, fuel
economy is noticeably lower than it was on this vehicle
at one time, as previously shown by an actual road test.
Important: Driving habits affect fuel economy. Check
the owner’s driving habits by asking the following ques-
tions:1. Is the A/C system (i.e. defroster mode) turned on all
the time?
2. Are the tires at the correct air pressure?
3. Have excessively heavy loads been carried?
4. Does the driver accelerate too much and too often?
Suggest the driver read the section in the owner’s
manual about fuel economy.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Inspect the air filter for excessive contamination.
2. Inspect for fuel system leaks.
Are all needed checks complete?
–
Go to Step 3
–
3
1. Inspect the spark plugs for excessive wear,
insulation cracks, improper gap, or heavy
deposits.
2. Replace any faulty spark plugs.
3. Inspect the ignition wires for cracking, hardness,
and proper connections.
Are all needed checks and repairs complete?
–
Go to Step 4
–
4
1. Inspect the engine coolant level.
2. Check the thermostat for being always open or for
an incorrect heat range.
3. Replace the thermostat as needed.
Are all needed checks and repairs complete?
–
Go to Step 4
–
5
1. Check the transaxle shift pattern. Ensure all
transaxle gears are functioning.
2. Check for proper calibration of the speedometer.
3. Check the brakes for dragging.
4. Check the cylinder compression.
5. Repair, replace, or adjust any components as
needed.
Are all checks and needed repairs complete?
–
System OK
–

2C –10 FRONT SUSPENSION
DAEWOO M-150 BL2
D106B511
FRONT LONGITUDINAL FRAME AND
STABILIZER SHAFT
Removal Procedure
1. Removed the front under longitudinal frame.

Raise and suitably support the vehicle.

Remove the front wheel. Refer to Section 2E, Tires
and Wheels.

Remove the transaxle under cover. Refer to Sec-
tion 5B, Manual Transaxle.

Remove the front under longitudinal frame bolt (1).

Remove the front under longitudinal frame nut (2).
D16B512A

Remove the stabilizer shaft mounting bolts (3).

Remove the front under longitudinal frame.
D106B513
2. Remove the stabilizer shaft from the vehicle.

Remove the cotter pin (1).

Remove the castellated nut (2).

Remove the washer (3).

Remove the rear bushing with separating the sta-
bilizer shaft from the control arm (4).
D16B514A

Remove the bushing (5).

Remove the wire clamps (6).

Remove the mountings (7).

FRONT SUSPENSION 2C–13
DAEWOO M-150 BL2
D106B523

Remove the strut bar bolts at driver side (4).
Important: When removing the bolts using the tool,
do not contact the battery terminal.

Remove the strut bar at passenger side
D16B524B
Installation Procedure
1. Install the strut bar to the vehicle.

Install the strut bar at passenger side.

Install the strut bar bolts at driver side (1).
Important: When installing the bolts using the tool, do
not contact the battery terminal.

Install the strut bar bolts at passenger side (2).

Install the A/C low pressure pipe bracket–to–strut
bar nut.
Tighten
Tighten the strut bar bolts to 35–55 Nm (25–41 lb-ft).

Install the purge control valve to the strut bar.
D106B525
CROSSMEMBER
Removal Procedure
1. Remove the transaxle under cover. Refer to Section
5B, Five–Speed Manual Transaxle.
2. Remove the front under longitudinal frame. Refer to
“Stabilizer Shaft” in this section.
3. Remove the damping bush bolt and nut.
D106B526
4. Disconnect the power steering pressure line from the
crossmember. Refer to Section 6B, Power Steering
Pump.
5. Remove the crossmember from the vehicle.

Place support jack under the crossmember.

Remove the bumper fascia screws.

Remove the rear bolts (1).

Remove the side bolts (2).

Lower the support jack and remove the crossmem-
ber from the vehicle.

DAEWOO M-150 BL2
SECTION 3B
MANUAL TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
Description and Operation 3B-2. . . . . . . . . . . . . . . . . .
Front Drive Axle 3B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 3B-3. . . . . . . . . . . . . . . . . . . . . . . .
Drive Axle Assembly 3B-3. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 3B-4. . . . .
Diagnosis 3B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 3B-5. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 3B-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Axle Assembly 3B-5. . . . . . . . . . . . . . . . . . . . . . . Unit Repair 3B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Joint 3B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Joint 3B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 3B-12. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 3B-12. . . . . . . . . .
Special Tools and Equipment 3B-13. . . . . . . . . . . . . .
Special Tools Table 3B-13. . . . . . . . . . . . . . . . . . . . . . .