check engine light DAEWOO MATIZ 2003 Service Manual PDF

1F–294 ENGINE CONTROLS
DAEWOO M-150 BL2
CUTS OUT, MISSES
Definition: Steady pulsation or jerking that follows en-
gine speed, usually more pronounced as engine load in-creases. The exhaust has a steady spitting sound at idle
or low speed.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
Check the ignition system voltage output for all of
the cylinders using a spark tester.
Is spark present on all of the cylinders?
–
Go to Step 3
Go to “Ignition
System Check”
3
1. Inspect the spark plugs for excessive wear,
insulation cracks, improper gap, or heavy
deposits.
2. Check the resistance of the ignition wires.
Replace any ignition wires that have a resistance
greater than the value specified.
Is the problem found?
30000 ΩGo to Step 4Go to Step 5
4Repair or replace any components as needed.
Is the repair complete?–System OK–
5
With the engine running, spray the ignition wires with
a fine water mist to check for arcing and shorting to
ground.
Is the problem found?
–
Go to Step 6Go to Step 7
6Replace the ignition wires.
Is the repair complete?–System OK–
7
1. Perform a cylinder compression test.
2. If the compression is low, repair the engine as
needed.
3. Inspect for proper valve timing, bent pushrods,
worn rocker arms, broken or weak valve springs,
and worn camshaft lobes.
4. Inspect the intake manifold and the exhaust
manifold passages for casting flash.
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 fuel system for a plugged in-line fuel
filter.
2. Check the fuel system for low fuel pressure. If the
fuel pressure is below the value specified, service
the fuel system as needed.
3. Inspect for contaminated fuel.
Is the problem found?
380 kPa
(55 psi)
Go to Step 10Go to Step 11
10Repair or replace any components as needed.
Is the repair complete?–System OK–
11
1. Disconnect all of the fuel injector harness
connectors at the fuel injectors.
2. Connect an injector test light to the harness
terminals of each fuel injector connector.
3. Note the test light while cranking the engine for
each fuel injector.
Does the test light blink for all of the fuel injectors?
–
Go to Step 13Go to Step 12

ENGINE CONTROLS 1F–295
DAEWOO M-150 BL2
Cuts Out, Misses (Cont’d)
StepActionValue(s)YesNo
12
1. Repair or replace the faulty injector drive circuit
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
–
13
Measure the resistance of each fuel injector.
Is the injector resistance within the value specified
(the resistance will increase slightly at higher
temperatures)?
11.6–12.4 ΩGo to Step 15Go to Step 14
14
Replace any fuel injectors 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
16Replace any restricted or leaking fuel injectors.
Is the repair complete?–System OK–
17
1. Check for electromagnetic interference.
2. Monitor the engine rpm with a scan tool.
Does the scan tool rpm change greatly with little
change in actual engine rpm?
–
Go to Step 18
–
18
1. Inspect the routing of the ignition wires.
2. Inspect all of the ignition system grounds.
3. Correct the routing or repair the ground
connections as needed.
Are all checks and needed repairs complete?
–
System OK
–

1F–298 ENGINE CONTROLS
DAEWOO M-150 BL2
Rough, Unstable, or Incorrect Idle, Stalling (Cont’d)
StepActionValue(s)YesNo
12
Is the long term fuel trim reading below the value
specified?
–20%
Go to
“Diagnostic Aids
for DTC P0172”
Go to Step 13
13
Is the long term fuel trim reading above the value
specified?
25%
Go to
“Diagnostic Aids
for DTC P0171”
–
14
1. Disconnect all of the fuel injector harness
connectors at the fuel injectors.
2. Connect an injector test light between the
harness terminals of each fuel injector connector.
3. Note the test light while cranking the engine.
Does the test light blink for all of the fuel injectors?
–
Go to Step 16Go to Step 15
15
1. Repair or replace the faulty injector drive circuit
harness, the connector, or the connector
terminals as needed.
2. If the harness, the connectors, and the terminals
are OK, replace the Engine Control Module
(ECM).
Is the repair complete?
–
System OK
–
16
Measure the resistance of each of the fuel injectors.
Is the resistance within the value specified (the
resistance will increase slightly at higher
temperatures)?
11.6–12.4 ΩGo to Step 18Go to Step 17
17
Replace any fuel injectors with a resistance that is
out of specifications.
Is the repair complete?
–
System OK
–
18Perform an injector diagnosis.
Is the problem found?–Go to Step 19Go to Step 20
19Replace any leaking or restricted fuel injectors.
Is the repair complete?–System OK–
20
1. With the engine OFF, disconnect the fuel
pressure regulator vacuum hose.
2. Thoroughly inspect the fuel pressure regulator
vacuum port and the fuel pressure regulator
vacuum hose for the presence of fuel.
Is the problem found?
–
Go to Step 21Go to Step 22
21Replace the fuel pressure regulator as needed.
Is the repair complete?–System OK–
22
1. Check the ignition system output voltage for all of
the cylinders using a spark tester.
2. Inspect the spark plugs for excessive wear,
insulation cracks, improper gap, or heavy
deposits.
3. Inspect the ignition wires for cracking, hardness,
or improper connections.
4. Replace any ignition wires with a resistance over
the value specified.
Is the problem found?
30000 ΩGo to Step 23Go to Step 24
23
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–

4A –4 HYDRAULIC BRAKES
DAEWOO M-150 BL2
DIAGNOSITIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:

Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally in-
flated, and the tread pattern of the right and the left
tires must be approximately equal.

Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.

Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any sus-
pected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or ex-
ternally. Refer to the procedure below to check the mas-
ter cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is nor-
mal, check the vacuum booster pushrod length. If an in-
correct pushrod length is found, adjust or replace the
rod.Check the master cylinder using the following proce-
dure:

Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are in-
dicated only if there is at least one drop of fluid. A
damp condition is not abnormal.

Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfac-
tory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rub-
ber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep al-
cohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylin-
der, and bleed the system. Refer to “Manual Bleeding
the Brakes” in this section.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as neces-
sary.

FIVE-SPEED MANUAL TRANSAXLE 5B–9
DAEWOO M-150 BL2
CHECKING FLUID LEVEL
Check for a leak in the area of transaxle case and seal-
ing and then check fluid level and condition after remov-
ing oil level plug.
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Remove the oil level plug and check the fluid level.
4. The fluid should slightly flow out from the oil level plug
hole.
5. If the level is low, add the recommended fluid through
the oil level plug hole until the fluid begins to run out.
6. If the fluid is contaminated or discolored, replace it
with the recommended fluid.
7. Reinstall the oil level plug and tighten it securely.
D103B301
CHANGING FLUID
1. Operate the engine until it comes to normal operating
temperature(Coolant temperature : 80~90°C (176~
194°F)).
2. Stall the engine and raise the vehicle.
3. Drain the fluid after removing the drain plug.
4. Reinstall the drain plug and tighten it securely after
coating sealant.
5. Remove the oil level plug and replenish the fluid until
it begins to run out.
a. Oil drain plug.
b. Oil level plug.
6. Reinstall the oil level plug and tighten it securely.Fluid Specification
75W-85(GL-4)
Fluid Capacity2.1L(2.21qt)
Service intervalRefer to Owner’s Manual
CHECKING TRANSAXLE NOISE
Many noises that appear to come from the transaxle
may actually originate with other sources such as tires,
road surfaces, wheel bearings, or engine and exhaust
system.
Identify the cause of any noise before attempting to re-
pair the clutch, the transaxle, or their related linkages.
To verify suspected transaxle noises,
1. Select a smooth, level asphalt road to reduce tyre
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lubri-
cants thoroughly.
3. Record the speed and the gear range of the transaxle
when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle oper-
ates in.

Drive – Under a light acceleration or a heavy pull.

Float – Maintaining a constant speed with a light
throttle on a level road.

Coast – With the transaxle in gear and the throttle
partly or fully closed.

All of the above.
CHECKING BEARING NOISE
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre-
loaded, a differential side bearing noise should not di-
minish much when the differential/transaxle is run with
the wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre-loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.

9B – 2 LIGHTING SYSTEMS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
HEADLAMPS AND PARKING LAMPS
The headlamps are controlled by the multifunction lever
located on the left side of the steering column. They will
come on with the ignition switch in any position. Turning
the headlamp switch to the first position turns on the
parking lamps, the license plate lamps and the instru-
ment panel illumination. Turning the switch to the sec-
ond position turns on all of the previous lamps and the
headlamps. Turning the switch to the off position turns
off all the lamps.
The parking lamps can be turned on by turning the light-
ing switch to the first position. The parking lamps can be
turned off by turning the switch to the OFF position.
Headlamp high beam and low beam are also controlled
by this lever. When the headlamps are on, pushing the
lever away from the driver until the switch clicks
changes the lamp from low beam to high beam. An indi-
cator lamp on the instrument cluster assembly will come
on when the high beam headlamps are on. To return the
headlamps to low beam, pull the lever toward the driver.
The headlamps must be aimed for proper illumination of
the road. Headlamp aim should be checked whenever a
new headlamp assembly is installed or service repairs to
the front end area may have disturbed the headlamp as-
sembly or its mountings.
FRONT TURN SIGNAL LAMPS
When the turn signals are activated, the side turn signal
lamps flash to signal a turn. The turn signal works only
when the ignition switch is on.
The turn signals are controlled by the light switch on the
left side of the steering column. Moving the lever all the
way up or down (past the detent) will turn on the turn sig-
nals. When the turn is completed, the lever will return to
horizontal and the turn signals will stop flashing.
For changing lanes or shallow turns where the steering
wheel does not turn far enough to cancel the signal,
move the signal only to the first detent and hold it there.
When the lever is released, it will return to horizontal and
the turn signal will cancel.
REAR FOG LAMP
The rear fog lamp is incorporated in the drive side tail-
lamp assembly and are controlled by the rear fog lamp
switch on the instrument panel. The rear fog lamp can
be turned on only when headlamps are on.
TAILLAMPS
The taillamps, stoplamps, backup lamp(s), rear fog lamp
(if equipped with) and turn signal lamps are one assem-
bly.
Turning on either the headlamps or the parking lamps
will also turn on the taillamps. When the brake pedal is
pushed, the taillamps will glow brighter to serve as sto-
plamps.
The center high-mounted stoplamp is located in the rear
window and will come on when the brake pedal is
pressed.
LICENSE PLATE LAMPS
The license plate lamps will come on when the head-
lamps or the parking lamps are on. The license plate
lamps are mounted on the rear bumper, above the li-
cense plate.
INTERIOR COURTESY LAMP
The courtesy lamp is located on the headliner just be-
fore the front seats. The lamp switch has three posi-
tions. If the switch is in the center position, the lamp will
go on whenever a door is opened and go off when it is
closed. In the ON position, the lamp will stay on until it is
turned off. In the OFF position, the lamp will not come
on, even when a door is opened.
BACKUP LAMP(S)
The backup lamps are located in the rear combination
lamps. They will come on when the transaxle is shifted
into REVERSE. On a vehicle with a manual transaxle,
they are activated by a reverse switch which is part of
the transaxle.
DAYTIME RUNNING LAMPS (DRL)
(W/Europe Only)
The daytime running lamps (DRL) work in conjunction
with the exterior lamps system. When the ignition switch
is turned to the ”II” position with the light switch off, park-
ing, tail, license plate and instrument panel lights illumi-
nate. And, when the engine is started, the headlamps
(low beam) also come on.
They remain on until the ignition switch is turned off or
the light switch is turned on. They revert to normal op-
eration when the light switch is on.
The daytime running lamps (DRL) is optional.

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
–

IMMOBILIZER ANTI-THEFT SYSTEM 9T–17
DAEWOO M–150 BL2
DTC 1601 – ECM Immobilizer Error (Incorrect 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.
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
1. Select CURRENT KEY STATUS from the scan
tool menu.
2. Read the STATUS OF CURRENT KEY message.
Does the KEY STATUS message indicate “KEY IS
WRONG”?
–
Go to “Key
Status Errors”
Go to Step 3
3
1. Select DIAGNOSIS from the scan tool menu.
2. Read the IMMO & ECM ID CODE (immobilization
and electronic control module identification code)
message.
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 electronic control
module (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 ID code.
Is the repair complete?
–
System OK
–

IMMOBILIZER ANTI-THEFT SYSTEM 9T–19
DAEWOO M–150 BL2
DTC 1602 – ECM Immobilizer Error (ECM Locked)
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.
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
1. Select CURRENT KEY STATUS from the scan
tool menu.
2. Read the STATUS OF CURRENT KEY message.
Does the KEY STATUS message indicate “KEY IS
WRONG”?
–
Go to “Key
Status Errors”
Go to Step 3
3
1. Select DIAGNOSIS from the scan tool menu.
2. Read the IMMO & ECM ID CODE (immobilization
and electronic control module identification code)
message.
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 electronic control
module (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 ID code.
Is the repair complete?
–
System OK
–

IMMOBILIZER ANTI-THEFT SYSTEM 9T–21
DAEWOO M–150 BL2
P 1628 – ECM Immobilizer Error (No Successful Communication)
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. Select immobilizer mode on the scan tool.
6. 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
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 3
3
Check for an open serial data wire between the
immobilizer control unit and the ECM.
Was the circuit open?
–
Go to Step 4Go to Step 5
4
Repair the open serial data wire between the ECM
and the immobilizer control unit.
Is the repair complete?
–
System OK
–
5
1. Replace the immobilizer.
2. Reprogram the identification (ID) code. Refer to
“Identification (ID) Code Reprogramming” in this
section.
Is the repair complete?
–
System OK
–
Go to Step 6
6
1. Replace the ECM.
2. Turn the ignition ON, OFF for more than 4
seconds.
3. Turn the ignition ON.
Is the repair complete?
–
System OK
–