Engine DAEWOO MATIZ 2003 Service Repair Manual

9N – 2 FRAME AND UNDERBODY
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
GENERAL BODY CONSTRUCTION
This vehicle is constructed with a unitized body which in-
corporates integral front and rear frame side rails.
The front suspension lower control arms are bolted to
and retained by supports, one each on the right and left
sides. The front suspension lower control arm supports
are attached to the underbody with three bolts at two
locations. The engine is bolted to the integral front side
rails. The suspension strut towers must be dimensional-
ly correct in relation to the remainder of the underbody in
order to maintain specified suspension strut and caster/
camber angles.
Since the individual underbody parts contribute directly
to the overall strength of the body, it is essential to ob-
serve proper welding techniques during service repairoperations. The underbody parts should be properly
sealed and rustproofed whenever body repair operations
destroy or damage the original sealing and rustproof-
ing. When rustproofing critical underbody parts, use a
good-quality type of air-dry primer, such as a corrosion-
resistant chromate or an equivalent material. Combina-
tion-type primer/surfacers are not recommended.
TRANSAXLE UNDER COVER
The transaxle under cover is one piece of steel that
serve as shields for the underside of the transaxle. The
covers help protect the engine from small rocks, gravel
and other objects that would otherwise come into con-
tact with the transaxle during normal driving conditions.

FRAME AND UNDERBODY 9N–3
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
ALIGNMENT CHECKING
An accurate method of determining the alignment of the
underbody uses a measuring tram gauge. The tram
gauge set used to perform the recommended measuring
checks must include a vertical pointer able to reach
457 mm (18 inches).
Two types of measurements can be made with a tram
gauge: direct point-to-point measurements and mea-
surements calculated on a horizontal plane (datum line)
parallel to the underbody. Point-to-point measurements
are generally taken on steering and suspension engine
compartment parts and simply require the vertical point-
ers to be set equally.
For horizontal plane measurements, the vertical pointers
must be set as specified for each point to be measured.
Dimensions-to-gauge holes are measured to the center
of the holes and flush to the adjacent surface metal un-
less otherwise specified. It is recommended that the di-
agonal dimensions to the cross-body be checked on
both sides in order to verify the dimensional accuracy of
the vehicle underbody.
FLOOR PAN INSULATORS
The floor pan insulators have been designed for the
higher floor pan temperatures that result from the use
of the catalytic converter in the exhaust system. There-
fore, when servicing a vehicle, it is essential that any in-sulators that may have been disturbed or removed be
reinstalled in the original sequence and location. Also, if
an insulator needs to be replaced, use only the insula-
tion specified for that location on the floor pan.
When servicing or replacing interior insulators, observe
the following instructions.

Install the insulators in the original position and se-
quence. Butt the pieces together in order to avoid
gapping or overlapping.

If it is necessary to replace an insulator, use only the
specified insulation.

Use the original part to determine the amount of re-
placement material required and as a template for
cutting and fitting the new piece to the floor pan.

When installing the insulator, do not enlarge any cut-
outs or holes that are used for the attachment of interi-
or parts such as the instrument panel or the floor
console.

Route the cross-body harness for interior parts over
the floor pan insulators. Clip it in the original location.

Do not apply spray-on deadeners or trim adhesives to
the top of the floor pan at the area directly over the
catalytic converter or the muffler.
Any insulator service repair or replacement should be
the same thickness, size, and location as the original
installation in the vehicle.

9R – 2 BODY FRONT END
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
BODY FRONT END
This vehicle has a unitized body with a frame assembly
supporting the engine and the transaxle. The fender
panels and the radiator support are also integral parts of
the body.

BODY FRONT END 9R–9
DAEWOO M-150 BL2
D109C538
HOOD LATCH RELEASE CABLE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the hood latch release cable from the instru-
ment panel. Refer to “Hood Latch Release Lever” in
this section.
2. Push the cable toward the engine compartment
through the body hole.
a. Hood latch lever cable.
D19C539B
3. Open and suitably support the hood.
4. Disconnect the hood latch release cable from the
hood latch. Refer to “Hood Latch” in this section.
5. Remove the hood latch release cable after removing
the plastic strip.
a. Hood latch release cable.
D19C539C
Installation Procedure
1. Connect the hood latch release cable to the hood
latch. Refer to “Hood Latch” in this section.
2. Arrange the hood latch release cable with the plastic
strip.
3. Push the cable toward the passenger compartment
through the body hole.
4. Connect the hood latch release cable to the hood
latch release lever. Refer to “Hood Latch Release Le-
ver” in this section.
D19C501A
FENDER
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheelhouse splash shield.

Remove the clip and the bolt.
a. Clip and bolt.

Remove the wheel house splash shield.
a. Wheel house splash shield.

IMMOBILIZER ANTI-THEFT SYSTEM 9T–11
DAEWOO M–150 BL2
The VIN code is calculated by the Immobilizer using a
random generator.
The VIN code is transmitted from the Immobilizer in the
release message communication only incase of using
an authorized key. Without an authorized key it is not
possible to getthe system VIN code.In case of ECM in-
ternal state is in Virgin mode or neutral mode the ECM
learns the system VIN code automatically after receiving
the first release response message.
To get a synchronized Immobilizer system (same VIN-
code in Immobilizer and ECM,authorized key) the DLC
test equipment has to be used for authorization of the
keys(first key coding). The usage of this test equipment
is restricted to authorized persons.

Communication with the DLC-test equipment. Main
functions are the key coding procedure, the VIN-code
handling and the support for system test functions.

Handling of the software watchdog
Operation
In the active mode of immobilizer (engine OFF, IG key
OFF) the status LED is blinking as mode A. When igni-
tion is turned ON, the system wakes up and tries to read
out the transponder.
In case of the detection of a valid key , The release mes-
sage communication with the ECM takes place. The sta-
tus LED displays the Immobilizer state “valid key”.
After turning off the ignition(ignition OFF detection simi-
lar to the ECM ignition OFF detection), the Immobilizer
changes to the active mode. The status LED is blinking
as Mode A.
Data Link Connector (DLC) Mode
When the ignition is on, a scan tool can switch the immo-
bilizer control unit to the DLC mode for diagnostics, key
coding and ID coding.

The status LED is turned off during DLC-mode

The Immobilizer will answer all correct messages,
which are defined as Immobilizer messages.
ID Code Handling
One of 65,535 VIN codes is stored in the immobilizer
EEPROM.
The VIN code can be erased by using “Reset VIN code”
command of the scan tool.
When the immobilizer control unit calculates a new VIN
code, ECM VIN code should be reset to get identical
with the immobilizer control unit’s.
During diagnostic procedures, the VIN code can be read
for comparison with the ECM VIN code by using the
scan tool’s “Read immobilizer control unit VIN code”
command.
SERIAL DATA LINK
Serial data can be exchanged between a scan tool and
the ECM and the Immobilizer control unit. The scan tool
connection is the data link connector (DLC).
ELECTRONIC CONTROL MOUDLE
(ECM)

ECM in Virgin mode
In this mode, the ECM knows only the model vehicle
identifier code.
The engine can be locked/unlocked.
ECM requests to ICU the VIN number. As soon as the
ECM receives two correct consecutive communica-
tion frames with the same VIN code the ECM learns
it.
The VIN code will be stored in non-volatile memory at
the end of power latch phase. ECM enters in Learnt
mode.

ECM in Learnt mode
In such a state, ECM checks on every communica-
tion, the correct encoding of the ICU.
If the code received is not correct, then the vehicle is
immobilized.
The coded 5 bytes of data emitted by ECM are a mix-
ture of MIN code and random.
The coded 5 bytes of data emitted by ICU are a mix-
ture of VIN code and random.

ECM in Neutral mode
This mode is a special intermediate mode, used for
ICU replacement or immobilizer option installation.
ECM request to ICU the VIN number. As soon as the
ECM receives two correct consecutive communica-
tion frames with the same VIN code the ECM learns
it. The VIN code will be stored in non-volatile memory
at the end of power latch phase. ECM enters in
Learnt mode.

After turning on the ignition the ECM will control the
engine in a normal way for starting and running while
waiting for a valid release response message from
the Immobilizer.
1. After receiving a response message including the in-
formation “ICU in learnt mode” and the correct sys-
tem VIN-code
→ the ECM enters the release state, which allows to
continue the running of the engine.
2. After receiving a response message including the in-
formation “ICU in learnt mode” and a wrong system
VIN-code
→ the ECM does not send a new request and enters
the blocked state, which causes the activation of the
immobilization actions of the engine.

9T–12 IMMOBILIZER ANTI-THEFT SYSTEM
DAEWOO M–150 BL2
3. If the ECM doesn’t receive a response message with-
in a defined time from beginning of the release time
period or the ECM receives a no release answer
→ the ECM enters the blocked state, which causes the
activation of the immobilization actions of the engine.

The inactive state of the Immobilizer (valid key/invalid
key) ends with turning off the ignition.
SECURITY INDICATOR
There is a security indicator on the instrument panel.
Status LED
An external LED displays the immobilizer system status.
The immobilizer contains the LED driver hardware for di-
rect connection of one LED.
Status LED Modes
Status
LEDImmobilizer
System StatusNote
BlinkingActive– Ignition OFF
BlinkingActive– Invalid key
detected
– Ignition ON
OFFInactive– Valid key detected
– Ignition ON
BlinkingActive– VIN-code is
different between
ICU and ECM in
learnt state
– Ignition ON
ONActive– Transponder
reading error
– Ignition ON
BlinkingActive– Reader exciter
ASIC error
– Ignition OFF

IMMOBILIZER ANTI-THEFT SYSTEM 9T–13
DAEWOO M–150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
IMMOBILIZER SYSTEM (FENIX 5MR)
The immobilizer anti-theft system requires diagnosis
when it is not possible to start the engine. If the no-start
condition occurs because of the immobilizer system, a
diagnostic trouble code (DTC) 1600, 1601 or
1602 should be set.
The immobilizer control unit monitors the detection and
the reading of the ignition key. The self-test capacity is
limited to those functions. Faults are communicated to a
scan tool during diagnosis, but they are not stored in the
immobilizer control unit’s memory.
Unauthorized use of a scan tool could be a method of
defeating the immobilizer anti-theft system, so certain
scan tool procedures require the use of a password. The
following functions are password protected:

Coding of an additional key.

Deleting all key codes.

Deletion of the immobilizer identification (ID) code.

Deletion of the electronic control module (ECM) ID
code.
The following functions do not require a password:

Reading an ignition key to determine if the transpond-
er is working or if a key is authorized.
Reading the immobilizer ID code to verify that it
matches the ECM ID code.
IMMOBILIZER SYSTEM (SIRIUS D3)
The immobilizer anti-theft system requires diagnosis
when it is not possible to start the engine. If the no-start
condition occurs because of the immobilizer system, a
diagnostic trouble code (P) 1628, 1629 should be set.
The immobilizer control unit monitors the detection and
the reading of the ignition key. The self-test capacity is
limited to those functions. Faults are communicated to a
scan tool during diagnosis, but they are not stored in the
immobilizer control unit’s memory.
Unauthorized use of a scan tool could be a method of
defeating the immobilizer anti-theft system, so certain
scan tool procedures require the use of a password. The
following functions are password protected:

Coding of an additional key.

Deleting all key codes.
The following functions do not require a password:

Reading an ignition key to determine if the transpond-
er is working or if a key is authorized.

Reading the immobilizer ID code to verify that it
matches the ECM ID code.

9T–14 IMMOBILIZER ANTI-THEFT SYSTEM
DAEWOO M–150 BL2
D19T002B
DIAGNOSTIC TROUBLE CODE (DTC) 1600
ECM IMMOBILIZER ERROR (NO ANSWER)
Circuit Description
When the ignition is turned ON, the key is tested by the
immobilizer anti-theft system. While the key code is be-
ing read by the immobilizer control unit, the engine can
start and run with any key that will turn the lock cylinder.
The key code is read and compared with key codes that
have been stored in the memory of the immobilizer con-
trol unit. If a valid key is detected, the immobilizer control
unit sends a serial data release message to the elec-
tronic control module (ECM). Included in the release
message is an identification (ID) code which assures
that neither the immobilizer control unit nor the ECM has
been substituted to defeat the system. If the ECM re-
ceives an invalid release message, the ECM performs
the following actions:
Disables the fuel injector circuit.

Disables the fuel pump circuit.

Disables the ignition coil.
DTC Will Set When

The ECM does not receive the signal from the immo-
bilizer control module when the ignition is turned on.

The above conditions are maintained until the ignition
is switched OFF.
DTC 1600 Will Clear When

The ignition switch is turned OFF or the scan tool
TROUBLE CODE CLEAR command is issued.

IMMOBILIZER ANTI-THEFT SYSTEM 9T–15
DAEWOO M–150 BL2
DTC 1600 – ECM Immobilizer Error (No Answer)
StepActionValueYesNo
1
Connect the scan tool using the following procedure:
1. Insert the cartridge into the scan tool.
2. Turn the ignition switch to the OFF position.
3. Connect the scan tool to the data link connector
(DLC).
4. Connect the scan tool’s power cord to the cigar
lighter socket.
5. Turn the ignition ON, but do not start the engine.
Is communication established between the scan tool
and the immobilizer control unit?
–
Go to Step 2
Go to
“Communi-
cation
Between
Immobilizer
and Test
Equipment”
2
Select CURRENT KEY STATUS from the scan tool
menu.
Did the STATUS OF CURRENT KEY message
indicate “KEY IS WRONG”?
–
Go to “Key
Status Errors”
Go to Step 3
3
Read the IMMO & ECM ID CODE message that
was displayed after requesting DIAGNOSIS.
Did the message differ from normal message?
Normal Message –ECM MODE: LEARNT
IMMO. MODE: LEARNT
VIN CODE: SAME
–
Go to
“Identification
(ID) Code
Repro-
gramming”
Go to Step 4
4
Check for an open serial data wire between the
immobilizer control unit and the ECM.
Was the circuit open?
–
Go to Step 5Go to Step 6
5
Repair the open serial data wire between the ECM
and the immobilizer control unit.
Is the repair complete?
–
System OK
–
6
1. Replace the ECM.
2. Reprogram the identification (ID) code. Refer to
“Identification (ID) Code Reprogramming” in this
section.
Is the repair complete?
–
System OK
–

9T–16 IMMOBILIZER ANTI-THEFT SYSTEM
DAEWOO M–150 BL2
D19T002B
DIAGNOSTIC TROUBLE CODE (DTC) 1601
ECM IMMOBILIZER ERROR (INCORRECT ANSWER)
Circuit Description
When the ignition is turned ON, the key is tested by the
immobilizer anti-theft system. While the key code is be-
ing read by the immobilizer control unit, the engine can
start and run with any key that will turn the lock cylinder.
The key code is read and compared with key codes that
have been stored in the memory of the immobilizer con-
trol unit. If a valid key is detected, the immobilizer control
unit sends a serial data release message to the elec-
tronic control module (ECM). Included in the release
message is an identification (ID) code which assures
that neither the immobilizer control unit nor the ECM has
been substituted to defeat the system. If the ECM re-ceives an invalid release message, the ECM performs
the following actions:

Disables the fuel injector circuit.

Disables the fuel pump circuit.

Disables the ignition coil.
DTC 1601 Will Set When

The ECM receives an incorrect release message
from the immobilizer control unit more than five times.
DTC 1601 Will Clear When

The ignition switch is turned OFF or the scan tool
TROUBLE CODE CLEAR command is issued.