light DAEWOO MATIZ 2003 Service Service Manual

ENGINE CONTROLS 1F–183
DAEWOO M-150 BL2
DTC P0400 – Electric Exhaust Gas Recirculation Out of Limit
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

ENGINE CONTROLS 1F–189
DAEWOO M-150 BL2
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 beeasily 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).
DTC P1403 – Electric Exhaust Gas Recirculation Valve Failure
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–

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

ENGINE CONTROLS 1F–197
DAEWOO M-150 BL2
DTC P1404 – Electric Exhaust Gas Recirculation Opend
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 with the engine
OFF.
2. Disconnect the EEGR valve electrical connector.
3. With a digital voltmeter (DVM) connected to
ground, probe the 5volt reference circuit at
terminal 2 to the EEGR valve.
Does the DVM read near the specified value?
5VGo to Step 4Go to Step 5
4
Jumper the 5 volt reference circuit to the signal
circuit at terminals 2 and 3.
Does the actual EEGR position display the specified
value ?
100%Go to Step 6Go to Step 7
5
1. Connect the test light to B+.
2. Probe the 5 volt reference circuit to the EEGR
valve.
Does the test light illuminate?
–
Go to Step 6Go to Step 7
6
Check the 5 volt reference and signal circuit for a
poor connection or proper terminal tension and
repair as necessary.
Is a repair necessary?
–
Go to Step 12Go to Step 7
7
1. Connect the test light to B+.
2. Probe the signal circuit at terminal 1 to the EEGR
valve.
Does the test light illuminate?
–
Go to Step 8Go to Step 9
8
Check for a high voltage in the EEGR valve 5 volt
reference circuit and repair as necessary.
Is a repair necessary?
–
Go to Step 12Go to Step 9
9Replace the EEGR valve.
Is a replacement complete?–Go to Step 12–
10
Check for a high voltage in the EEGR valve signal
circuit and repair as necessary
Is a repair necessary?
–
Go to Step 12Go to Step 11
11Replace the engine control module(ECM).
Is a replacement complete?–Go to Step 12–
12
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 13Go to Step 2

ENGINE CONTROLS 1F–201
DAEWOO M-150 BL2
DTC P0405 – EEGR Pintle Position Sensor Low 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 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 with the engine
OFF.
2. Disconnect the EEGR valve electrical connector.
3. With a digital voltmeter (DVM) connected to
ground, probe the 5volt reference circuit at
terminal 3 to the EEGR valve.
Does the DVM read near the specified value?
–0.01VGo to Step 4Go to Step 5
4
Jumper the 5 volt reference circuit to the signal
circuit at terminals 2 and 3.
Does the actual EEGR position display the specified
value ?
100%Go to Step 6Go to Step 7
5
1. Connect the test light to B+.
2. Probe the 5 volt reference circuit to the EEGR
valve.
Does the test light illuminate?
–
Go to Step 6Go to Step 7
6
Check the 5 volt reference and signal circuit for a
poor connection or proper terminal tension and
repair as necessary.
Is a repair necessary?
–
Go to Step 12Go to Step 7
7
1. Connect the test light to B+.
2. Probe the signal circuit at terminal 2 to the EEGR
valve.
Does the test light illuminate?
–
Go to Step 8Go to Step 9
8
Check for a low voltage in the EEGR valve 5 volt
reference circuit and repair as necessary.
Is a repair necessary?
–
Go to Step 12Go to Step 9
9Replace the EEGR valve
Is a replacement complete?–Go to Step 12–
10
Check for a low voltage in the EEGR valve signal
circuit and repair as necessary
Is a repair necessary?
–
Go to Step 12Go to Step 11
11Replace the engine control module(ECM).
Is a replacement complete?–Go to Step 12–
12
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 13Go to Step 2

ENGINE CONTROLS 1F–205
DAEWOO M-150 BL2
DTC P0406 – EEGR Pintle Position 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 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 with the engine
OFF.
2. Disconnect the EEGR valve electrical connector.
3. With a digital voltmeter (DVM) connected to
ground, probe the 5volt reference circuit at
terminal 3 to the EEGR valve.
Does the DVM read near the specified value?
More than 5VGo to Step 4Go to Step 5
4
Jumper the 5 volt reference circuit to the signal
circuit at terminals 2 and 3.
Does the actual EEGR position display the specified
value ?
100%Go to Step 6Go to Step 7
5
1. Connect the test light to B+.
2. Probe the 5 volt reference circuit to the EEGR
valve.
Does the test light illuminate?
–
Go to Step 6Go to Step 7
6
Check the 5 volt reference and signal circuit for a
poor connection or proper terminal tension and
repair as necessary.
Is a repair necessary?
–
Go to Step 12Go to Step 7
7
1. Connect the test light to B+.
2. Probe the signal circuit at terminal 2 to the EEGR
valve.
Does the test light illuminate?
–
Go to Step 8Go to Step 9
8
Check for a high voltage in the EEGR valve 5 volt
reference circuit and repair as necessary.
Is a repair necessary?
–
Go to Step 12Go to Step 9
9Replace the EEGR valve
Is a replacement complete?–Go to Step 12–
10
Check for a high voltage in the EEGR valve signal
circuit and repair as necessary
Is a repair necessary?
–
Go to Step 12Go to Step 11
11Replace the engine control module(ECM).
Is a replacement complete?–Go to Step 12–
12
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 13Go to Step 2

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–227
DAEWOO M-150 BL2
a Freeze Frame conditions (rpm, load, vehicle speed, temperature, etc.) that .are noted. This will isolate when
the DTC failed.
DTC P0480 – Low Speed Cooling Fan Relay Circuit Fault (WITHOUT A/C)
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 with the engine
OFF.
2. Install a scan tool.
3. Command the relay ON and OFF.
Does the relay turn ON and OFF when
commanded?
–
Go to Step 3Go to Step 5
3
1. Turn the ignition switch to LOCK.
2. Disconnect the engine control module (ECM)
connector.
3. Turn the ignition switch to ON.
4. Using a digital voltmeter(DVM), measure the
current in low speed relay control circuit, at
terminal 39 to ground for 2 minutes.
Does the amperage measure less than the specified
value?
0.75 amps
Go to
“Diagnostic
Aids”
Go to Step 4
4
1. Turn the ignition switch to LOCK.
2. Disconnect the relay.
3. Using a DVM, measure the resistance between
terminals 87 and 39 in the relay control circuit in
the ECM harness connector to ground.
Does the DVM display infinite resistance?
–
Go to Step 12Go to Step 10
5
1. Turn the ignition switch to LOCK.
2. Disconnect the relay.
3. Connect a test light between the relay coil
terminals 30 and 87 in the relay harness
connector.
4. Turn the Turn the ignition switch to ON.
5. Using the scan tool, command the relay ON and
OFF.
Does the test light turn ON and OFF with each
commanded?
–
Go to Step 8Go to Step 6
6
With the test light connected to ground, probe the
ignition feed circuit in the relay harness connector.
Does the test light illuminate?
–
Go to Step 7Go to Step 11
7
1. Turn the ignition switch to LOCK.
2. Reconnect the relay.
3. Disconnect the ECM connector containing the
relay control circuit.
4. Turn the Turn the ignition switch to ON.
5. With a fused jumper wire connected to ground,
probe the relay control circuit at terminal 39 in the
ECM harness connector.
Does the relay operate?
–
Go to Step 9Go to Step 10
8Check the connections at the relay.
Is a problem found and corrected?–Go to Step 14Go to Step 12