DAEWOO MATIZ 2003 Service Repair Manual

ENGINE CONTROLS 1F–303
DAEWOO M-150 BL2
BACKFIRE
Definition: Fuel ignites in the intake manifold, or in the
exhaust system, making a loud popping noise.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. Inspect for crossed or crossfiring ignition wires.
2. Check the ignition system output voltage for all
cylinders using a spark tester.
3. Inspect the spark plugs for excessive wear,
burned electrodes, improper gap, or heavy
deposits.
Is the problem found?
–
Go to Step 3Go to Step 4
3
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–
4
1. Check the fuel system operation.
2. Check the fuel injectors by performing an injector
diagnosis.
Is the problem found?
–
Go to Step 5Go to Step 6
5
Repair or replace any fuel system components as
needed.
Is the repair complete?
–
System OK
–
6
1. Inspect the Electric Exhaust Gas Recirculation
(EEGR) gasket for a leak or a loose fit.
2. Check the EEGR valve for proper operation.
3. Inspect the intake manifold and the exhaust
manifold for a casting flash.
Is the problem found?
–
Go to Step 7Go to Step 8
7Repair or replace any components as needed.
Is the repair complete?–System OK–
8
1. Inspect the timing belt for proper installation and
tension.
2. Check the engine compression.
3. Inspect the intake manifold gasket and the
exhaust manifold gasket for leaks.
4. Check for sticking or leaking valves.
5. Repair or replace any components as needed.
Are all checks and corrections complete?
–
System OK
–

1F–304 ENGINE CONTROLS
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
D102F502
D102F501
FUEL PUMP
Tools Required
DW 140–010A Fuel Pump Lock Ring Remover/Installer.
Removal Procedure
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
1. Relieve the fuel system pressure.
Start the engine and remove the rear seat cushon
(1).
Remove the fuel pump access cover (2).
Disconnect the fuel pump assembly electrical con-
nector lock pin (3).
Disconnect the fuel pump assembly electrical con-
nector (4).
Crank the engine for an additional 10 seconds.
D102F503
2. Disconnect the fuel lines from the fuel pump.
Disconnect the fuel outlet line (1).
Disconnect the fuel tank return line (2).

ENGINE CONTROLS 1F–305
DAEWOO M-150 BL2
D12F504A
3. Remove the fuel pump assembly from the tank.
Install the fuel pump lock ring remover/installer DW
140– 010A.
Turn the fuel tank lock ring counterclockwise (1).
D102F505
Remove the fuel pump assembly (2).
Remove the fuel pump gasket (3).
D102F506
Installation Procedure
1. Install in the reverse order of removal.
2. Perform an operational check of the fuel pump.
Perform an operational check of the ignition switch
ON the 2 seconds fuel pump operation.
D102F507
FUEL PRESSURE REGULATOR
Removal Procedure
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
1. Relieve the fuel system pressure after remove the
fuel pump assembly. Refer to “Fuel Pump” in this
section.

1F–306 ENGINE CONTROLS
DAEWOO M-150 BL2
D102F508
2. Remove the fuel pressure regulator from the fuel
pump.
Remove the retainer from the fuel pump assembly
(1).
Remove the fuel pressure regulator (2).
Check the O–ring seals for the damage or the rip.
Use a vacuum gauge to check the diaphram for
damage and the spring for operation.
D102F509
Installation Procedure
1. Install in the reverse order of removal.
Do not reuse the removed O–ring seals. Replace
the removed O–ring seals with the new ones.
D102F511
D102F510
FUEL FILTER
Removal Procedure
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
1. Relieve the fuel system pressure.
Refer to “Fuel Pump” in this section.
2. Remove the fuel filter from the fuel tank.
Disconnect the inlet/outlet fuel lines by pushing the
line connector lock and pulling off the hose of the
fuel filter tube (1).
Remove the screw from the retaining clamp (2).
Remove the fuel filter (3).

ENGINE CONTROLS 1F–307
DAEWOO M-150 BL2
D102F512
Installation Procedure
1. Install in the reverse order of removal.
Install the new fuel filter into the retaining clamp.
Note the flow direction.
Connect the inlet/outlet lines. Secure the lines with
the connector lock.
Perform a leak test of the fuel filter.
D102F514
D102F513
FUEL TANK
Removal Procedure
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
1. Relieve the fuel system pressure.
Refer to “Fuel Pump” in this section.
2. Disconnect the fuel tank ventilation tube.
Disconnect the clamp (1).
Disconnect the ventilation tube (2).
3. Drain the fuel tank.
Place a pan below the fuel tank to catch the drain-
ing fuel.
Disconnect the fuel tank filter tube (1).
Drain the fuel from the fuel tank using the ventila-
tion tube joint port (2).
Disconnect the evaporative emission canister line
(3).
D12F515A
4. Remove the fuel filter. Refer to “Fuel Filter” in this
section.
5. Install the jack to remove the fuel tank.
Install the jack on the center of the fuel tank.
Remove the strap bolts (1).
Remove the straps (2).

1F–308 ENGINE CONTROLS
DAEWOO M-150 BL2
D102F516
6. Remove the fuel tank.
Lower slowly the jack to remove the fuel tank easi-
ly (1).
Disconnect the canister hose which is connected
to the roll over valve from the fuel tank removed
(2).
Inspect the fuel tank for clacks, damages, and con-
taminations.
Inspect the fuel lines for cracks and damages.
D12F517A
Installation Procedure
1. Install in the reverse order of removal.
After the installation is complete, start the engine
to prevent the vapor lock and check the hoses for
leaks.
2. Install the fuel tank strap bolts.
Tighten
Tighten the fuel tank strap bolts to 18–22 Nm (13–16
lb-ft).
D102F519
D102F518
FUEL RAIL AND INJECTORS
Removal Procedure
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
1. Relieve the fuel system pressure.
Refer to “Fuel Pump” in this section.
2. Remove the canister from the engine room. Refer to
“Evaporative Emission Canister” in this section.
3. Disconnect the fuel inlet line (1).
4. Disconnect the fuel injector harness connectors (2).

ENGINE CONTROLS 1F–309
DAEWOO M-150 BL2
D102F520
5. Remove the fuel rail with the fuel injectors attached.
Remove the bolts (1).
Remove the fuel rail with the fuel injectors attached
(2).
Notice: Before removal, the fuel rail assembly may be
cleaned with a spray–type cleaner, following package in-
structions. Do not immerse the fuel rails in liquid clean-
ing solvent. Use care in removing the fuel rail assembly
to prevent damage to the electrical connectors and the
injector spray tips. Prevent dirt and other contaminants
from entering open lines and passages. Fittings should
be capped and holes plugged during service.
D102F521
6. Remove the injectors from the fuel rail.
Remove the fuel injector retainer clips (1).
Remove the fuel injectors by pulling them down
and out (2).
Discard the fuel injector O–rings (3).
Important: Different fuel injectors are calibrated for dif-
ferent flow rates. When ordering new fuel injectors, be
certain to order the identical part number that is in-
scribed on the old fuel injector.
D12F522A
18–22 Nm
Installation Procedure
1. Install in the reverse order of removal.
Important: If a fuel injector becomes separated from
the fuel rail and remains in the cylinder head, replace the
fuel injector O–ring seals and the retaining clip.
Lubricate the new fuel injector O–rings with engine
oil. Install the new O–rings on the fuel injectors.
2. Install the fuel rail retaining bolts.
Tighten
Tighten the fuel rail retaining bolts to 18–22 Nm
(13–16 lb-ft).
3. Perform a leak check of the fuel rail and the fuel injec-
tors.
MAA1F400
EVAPORATIVE EMISSION CANISTER
Removal Procedure
Caution: Canister and vacuum hoses contain fuel
vapors. Do not smoke in the area or permit an open
flame.
1. Disconnect the negative battery cable.
2. Remove the canister.
Remove the bolt (1).
Remove the nut, then remove the cover (2).

1F–310 ENGINE CONTROLS
DAEWOO M-150 BL2
MAA1F410
Disconnect the canister hoses (3).
Remove the evaporative emission casnister (4).
MAA1F420
Installation Procedure
1. Install in the reverse order of removal.
MAA1F430
EVAPORATIVE EMISSION CANISTER
PURGE SOLENOID
1. Disconnect the negative battery cable.
2. Disconnectthe evaporative (EVAP) emission canister
purge solenoid connector.
3. Disconnect the vacuum hoses from the EVAP canis-
ter purge solenoid.
4. Unclip the EVAP emission canister purge solenoid
from the mounting bracket.
5. Installation should follow the removal procedure in
the reverse order.
MAA1F440
MANIFOLD ABSOLUTE PRESSURE
SENSOR
Removal Procedure
1. Disconnect the manifold absolute pressure (MAP)
sensor connector and vacuum hose.
Disconnect the MAP connector (1).
Disconnect the vacuum hose from the MAP sensor
(2).

ENGINE CONTROLS 1F–311
DAEWOO M-150 BL2
MAA1F450
2. Remove the MAP sensor.
Remove the bolts (1).
Remove the MAP sensor with bracket (2).
MAA1F460
Installatin Procedure
1. Install in the reverse order of removal.
Inspect the MAP sensor vacuum hose for the tear
and damages.
2. Install the MAP sensor with the bolts and nuts.
Tighten
Tighten the MAP sensor bolts/nuts to 8–12 Nm
(71–106 lb-in).
Tighten the MAP sensor bracket bolt to 8–12 Nm
(71–106 lb-in).
D102F537
THROTTLE BODY
Removal Procedure
1. Remove the air cleaner/resonator assembly and air
intake tube. Refer to Section 1B, SOHC Engine Me-
chanical.
2. Drain the engine coolant. Refer to Section 1D, Engine
Cooling.
D102F538
3. Disconnect the throttle cable, the throttle position
sensor and the idle air control valve connectors.
Open the throttle valve (1).
Disconnect the throttle cable (2).
Disconnect the idle air control valve connector (3).
Disconnect the throttle position sensor connector
(4).

1F–312 ENGINE CONTROLS
DAEWOO M-150 BL2
D102F539
4. Disconnect the coolant hoses and vacuum hoses
from the throttle body.
Loosen the clamps from the coolant hoses (1).
Disconnect the coolant hoses from the throttle
body (2).
Disconnect the vacuum hoses (3).
D102F541
5. Remove the throttle body from the intake manifold.
Remove the throttle body bolts (1).
Remove the throttle body (2).
Discard the throttle body gasket (3).
Inspect the throttle body gasket for the deforma-
tion and the damages.
9–12 Nm
D12F542A
Installation Procedure
1. Install in the reverse order of removal.
Important: Make sure the throttle control cable do not
hold the throttle open. With the engine OFF, check to
see that the accelerator pedal is free.
2. Install the throttle body with the bolts.
Tighten
Tighten the throttle body bolts to 9–12 Nm (80–106
lb-in).
D12F543A
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
Removal Procedure
1. Remove the engine coolant temperature (ECT) sen-
sor. Refer to Section 1D, Engine Coolings.