filter DAEWOO NUBIRA 2004 Service User Guide

1F – 10IENGINE CONTROLS
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Camshaft Position Sensor Bolts (1.4L/1.6L DOHC)7–62
Camshaft Position Sensor Bolts (1.8 DOHC)8–71
Crankshaft Position Sensor Retaining Bolt (1.4L/1.6L DOHC)6.5–58
Crankshaft Position Sensor Retaining Bolt (1.8 DOHC)8–71
Electronic Ignition System Ignition Coil Retaining Bolts10–89
Exhaust Gas Recirculation Valve Retaining Bolts3022–
Engine Control Module Bolts12–106
Engine Coolant Temperature Sensor Bolt (1.4L/1.6L DOHC)17.513–
Engine Coolant Temperature Sensor Bolt (1.8 DOHC)2015–
Evaporative Emission Canister Flange Bolt4–35
Evaporative Emission Canister Purge Solenoid Bracket Bolt5–44
Fuel Filter Mounting Bracket Assembly Bolt4–35
Fuel Tank Retaining Bolts2015–
Fuel Rail Retaining Bolts2518–
Idle Air Control Valve Retaining Bolts (1.8 DOHC)3–27
Intake Air Temperature Sensor2216–
Knock Sensor Bolt2015–
Manifold Absolute Pressure Sensor Bolts (1.4L/1.6L DOHC)8–71
Manifold Absolute Pressure Sensor Bolts (1.8 DOHC)4–35
Oxygen Sensor Bolt4231–
Throttle Body Retaining Nuts (1.4L/1.6L DOHC)1511–
Throttle Body Retaining Nuts (1.8 DOHC)10–89
Throttle Position Sensor Retaining Bolts (1.8 DOHC)2–18

1F – 42IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
191. Measure the resistance between following ter-
minals:
S Terminal 1 and 2 of ignition coil.
S Terminal 2 and 1 of ignition coil.
Are the resistance within the value specified.
1. Remove the high tension cable.
2. Measure the resistance between second coil.
S Between 1 and 4
S Between 2 and 3
Are the resistance within the value specified.0.9 W
5.3 kWGo to Step 21Go to Step 20
20Replace the EI system ignition coil.
Is the repair complete?–Go to Step 2–
211. Check for any damages or poor connection in
ignition wires and repair as needed.
2. Connect the EI system ignition coil connector
and ECM connector.
3. Check for the presence of spark from all of the
ignition wires.
Is the spark present from all of the ignition wires?–Go to Step 2Go to Step 22
22Replace ECM.
Is the repair complete?–Go to Step 2–
231. Turn the ignition OFF.
2. Connect a fuel pressure gauge.
3. Crank the engine.
Is any fuel pressure present?–Go to Step 26Go to Step 24
241. Turn the ignition OFF.
2. Disconnect the electrical connector at the fuel
pump.
3. Connect a test light between the fuel pump ter-
minals 2 and 3.
4. Turn the ignition ON.
5. With the ignition ON, the test light should light
for the time specified.
Is the test light on?2 sec.Go to Step 25Go to 34
25Replace the fuel pump.
Is the repair complete?–Go to Step 2–
26Is the fuel pressure within the value specified?283–324 kPa
(41–47 psi)Go to Step 27Go to Step 29
27Check the fuel for contamination.
Is the fuel contaminated?–Go to Step 28Go to Step 41
281. Remove the contaminated fuel from the fuel
tank.
2. Clean the fuel tank as needed.
Is the repair complete?–Go to Step 2–
291. Check the fuel filter for restriction.
2. Inspect the fuel lines for kinks and restrictions.
3. Repair or replace as needed.
4. Measure the fuel pressure.
Is the fuel pressure within the value specified?283–324 kPa
(41–47 psi)Go to Step 2Go to Step 30

ENGINE CONTROLS 1F – 43
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
301. Disconnect vacuum line from the fuel pressure
regulator.
2. Inspect the vacuum line for the presence of
fuel.
3. Inspect the fuel pressure regulator vacuum port
for the presence of fuel.
Is any fuel present?–Go to Step 31Go to Step 32
31Replace the fuel pressure regulator.
Is the repair complete?–Go to Step 2–
321. Remove the fuel pump assembly from the fuel
tank.
2. Inspect the fuel pump sender and the fuel cou-
pling hoses for a restriction.
3. Inspect the in–tank fuel filter for restriction.
Is the problem found?–Go to Step 33Go to Step 25
33Replace the fuel pump sender, the in–tank fuel filter,
and/or the fuel coupling hoses as needed.
Is the repair complete?–Go to Step 2–
341. Turn the ignition OFF.
2. Disconnect the electric connector at the fuel
pump.
3. Connect a test light between fuel pump con-
nector terminal 3 and ground.
4. Turn the ignition ON.
5. With the ignition ON, the test light should illumi-
nate for the time specified.
Is the test light on?2 secGo to Step 35Go to Step 36
35Repair the open circuit between the fuel pump con-
nector terminal 2 and ground.
Is the repair complete?–Go to Step 2–
361. Turn the ignition OFF.
2. Disconnect the fuel pump relay.
3. Turn the ignition ON.
4. Measure the voltage at terminal 30 and 86 of
fuel pump relay.
Is the voltage within the value specified?11–14 VGo to Step 38Go to Step 37
37Repair open or short circuit for power supply.
Is the repair complete?–Go to Step 2–
381. Turn the ignition OFF.
2. Disconnect ECM connector.
3. Using an ohmmeter, measure the resistance
between following terminals.
S Terminal 6 of ECM and terminal 85 of fuel
pump relay.
S Terminal 87 of fuel pump relay and terminal
3 of fuel pump.
Does the resistance within the value specified?0 WGo to Step 40Go to Step 39

1F – 50IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
35While cranking the engine, measure the voltage at
the EI system ignition coil connector terminal 3 .
Does the voltage fluctuate within the values speci-
fied?0.2–2.0 vGo to Step 39Go to Step 37
36Check for an open in the wire from the EI system
ignition coil connector terminal 1 to the ECM connec-
tor terminal M51.
Is the problem found?–Go to Step 38Go to Step 40
37Check for an open in the wire from the EI system
ignition coil connector terminal 3 to the ECM connec-
tor terminal M1.
Is the problem found?–Go to Step 38Go to Step 40
381. Repair the wiring as needed.
2. Connect the EI system ignition coil connector.
3. Check for the presence of spark from all of the
ignition wires.
Is spark present from all of the ignition wires?–Go to Step 3Go to Step 39
39Replace the EI system ignition coil.
Is the repair complete?–Go to Step 3–
401. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?–Go to Step 3–
411. Turn the ignition OFF.
2. Connect a fuel pressure gauge.
3. Crank the engine.
Is any fuel pressure present?–Go to Step 44Go to Step 42
421. Turn the ignition OFF.
2. Disconnect the electrical connector at the fuel
pump.
3. Connect a test light between the fuel pump
connector terminals 3 and 2.
4. Turn the ignition ON.
5. With the ignition ON, the test light should light
for the time specified.
Is the test light on?2 secGo to Step 43Go to Step 53
43Replace the fuel pump.
Is the repair complete?–Go to Step 3–
44Is the fuel pressure within the value specified?283–324 kPa
(41–47 psi)Go to Step 48Go to Step 45
451. Check the fuel filter for a restriction.
2. Inspect the fuel lines for kinks and restrictions.
Is the problem found?–Go to Step 46Go to Step 47
461. Disconnect the vacuum line from the fuel pres-
sure regulator.
2. Inspect the vacuum line for the presence of
fuel.
3. Inspect the fuel pressure regulator vacuum port
for the presence of fuel.
Is any fuel present?283–324 kPa
(41–47 psi)Go to Step 3Go to Step 47

ENGINE CONTROLS 1F – 51
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
471. Disconnect the vacuum line from the fuel pres-
sure regulator.
2. Inspect the vacuum line for the presence of
fuel.
3. Inspect the fuel pressure regulator vacuum port
for the presence of fuel.
Is any fuel presen–Go to Step 50Go to Step 51
48Check the fuel for contamination.
Is the fuel contaminated?–Go to Step 49Go to Step 65
491. Remove the contaminated fuel from the fuel
tank.
2. Clean the fuel tank as needed.
Is the repair complete?–Go to Step 3–
50Replace the fuel pressure regulator.
Is the repair complete?–Go to Step 3–
511. Remove the fuel pump assembly from the fuel
tank.
2. Inspect the fuel pump sender and the fuel cou-
pling hoses for a restriction.
3. Inspect the in–tank fuel filter for a restriction.
Is the problem found?–Go to Step 52Go to Step 43
52Replace the fuel pump sender, the in–tank fuel filter,
and/or the fuel coupling hoses as needed.
Is the repair complete?–Go to Step 3–
531. Turn the ignition OFF.
2. Disconnect the electrical connector at the fuel
pump.
3. Connect a test light between the fuel pump
connector terminal 3 and a known good
ground.
4. Turn the ignition ON.
5. With the ignition ON, the test light should light
for the time specified.
Is the test light on?2 secGo to Step 54Go to Step 55
54Repair the open wire between the fuel pump connec-
tor terminal 2 and ground.
Is the repair complete–Go to Step 3–
551. Turn the ignition OFF.
2. Disconnect the fuel pump relay.
3. Connect a test light between the fuel pump
relay connector terminal 85 and ground.
4. Turn the ignition ON.
Is the test light on?2 secGo to Step 56Go to Step 62
561. Turn the ignition OFF.
2. Connect a test light between the fuel pump
relay connector terminal 86 and battery posi-
tive.
3. Turn the ignition ON.
4. With the ignition ON, the test light should light
for the time specified.
Is the test light on?–Go to Step 57Go to Step 61

ENGINE CONTROLS 1F – 145
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0135
FRONT HEATED OXYGEN SENSOR HEATER CIRCUIT
NOT FUNCTIONING
Circuit Description
Heated oxygen sensors (HO2S) are used for fuel control
and post catalyst monitoring. Each HO2S compares the
oxygen content of the surrounding air with the oxygen con-
tent in the exhaust stream. The HO2S must reach operat-
ing temperature to provide an accurate voltage signal. A
heating element inside the HO2S minmizes the time re-
quired for the sensor to reach operating temperature. Volt-
age is provided to the heater by the ignition 1 voltage cir-
cuit through a fuse. With the engine running, ground is
provided to the heater by the HO2S heater low control cir-
cuit, through a low side driver within the engine control
module (ECM). The ECM monitors the current flow
through the heater for diagnosis.
If the ECM detects that the HO2S heater current is above
or blelow a specified range, DTC P0135 seats.
Conditions for Setting the DTC
S DTCs P0106, P0117, P0118, P1017 are not set.
S Engine run time is greater than 30 seconds.
S Filtered O2 heater current is less than 0.1 amps.
Action Taken When the DTC SetsS The Malfunction Indicator Lamp (MIL) will illuminate
after three consecutive trip with a fail.
S 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.
S A history Diagnostic Trouble Code (DTC) is stored.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after three consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.
Diagnostic Aids
An intermittent may be caused by rubbed through wire in-
sulation or a wire contacting the exhaust.
Check for poor connection or damaged harness – inspect
harness connectors for the following conditions:
S Improper mating
S Broken locks
S Improperly formed
S Damaged terminals
S Poor terminal–to–wire connection

ENGINE CONTROLS 1F – 163
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
3With the engine running, operate the vehicle until the
LOOP STATUS indicates closed.
Is the Long Term Fuel Trim value above the specified
value?–30%Go to Step 4Go to Step 5
41. Turn the ignition switch ON, with the engine
OFF.
2. Review the Freeze Frame data and note the
parameters.
3. Operate the vehicle within the Freeze Frame
conditions and Conditions for Setting The DTC
as noted.
Does the Long Term Fuel Trim value above the spe-
cified value while operating under the specified con-
ditions?–30%Go to Step 21Go to Step 5
5Visually/physically check the air cleaner filter for ex-
cessive dirt or being plugged and repair as needed.
Is the repair complete?–Go to Step 21Go to Step 6
6Visually/physically check the air intake system for
collapsed or restricted and repair as needed.
Is the repair complete?–Go to Step 21Go to Step 7
7Inspect the throttle body inlet for damaged or foreign
objects which may partially block the airflow and re-
pair as needed.
Is the repair complete?–Go to Step 21Go to Step 8
81. Turn the ignition OFF.
2. Inspect the throttle bore, throttle plate and Idle
Air Control (IAC) passages for clocking and
foreign objects and repair as needed.
Is the repair complete?–Go to Step 21Go to Step 9
9Start the engine with the vehicle in park or neutral
and A/C off and note the idle quality.
Is a low or unsteady idle being experienced?–Go to Step 10Go to Step 12
10Idle the engine.
Are the IAC counts below the specified value?100Go to Step 12Go to Step 11
111. Turn the ignition OFF.
2. Disconnect the Manifold Absolute Pressure
(MAP) sensor electrical connector.
3. Start the engine.
4. Operate the vehicle in Closed Loop while moni-
toring the Long Term Fuel Trim value.
Does the Long Term Fuel Trim value increase above
the specified value?–30%Go to Step 20Go to Step 12
12Check the IAC valve performance. Refer to ”DTC
P0506 Idle Speed RPM Lower Than Desired Idle
Speed” or ”DTC P0507 Idle Speed RPM Higher
Than Desired Idle Speed” in this section and repair
as necessary.
Is the repair complete?–Go to Step 21Go to Step 13

ENGINE CONTROLS 1F – 195
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0327
KNOCK SENSOR CIRCUIT FAULT (1.4L DOHC)
Circuit Description
The knock sensor (KS) system is used to detect engine
detonation, allowing the engine control module (ECM) to
retard ignition control spark timing based on the KS signal
being received. The KS produces an AC signal so that un-
der a no knock condition the signal on the KS circuit mea-
sures about 0.007V AC. The KS signal’s amplitude and
frequency depend upon the amount of knock being experi-
enced. The ECM contains a non–replaceable knock filter
module called a signal–to–noise enhancement filter
(SNEF) module. This filter module in the ECM determines
whether knock is occurring by comparing the signal level
on the KS circuit with the voltage level on the noise chan-
nel. The noise channel allows the ECM to reject any false
knock signal by knowing the amount of normal engine me-
chanical noise present. Normal engine noise varies de-
pending on engine speed and load. When the ECM deter-
mines that an abnormally low noise channel voltage level
is being experienced, a DTC P0327 will set.
Conditions for Setting the DTC
S The knock sensor SPI bus in failure during 8 sec-
onds.
Or
S The knock sensor voltage is less than 0.3V.
S The engine coolant temperature is greater than
60°C (145°F).
S The engine speed is greater than 1,500 rpm.
S The mass air flow is higer than 180mg/tdc.
Or
S When difference between a original signal valve
and filtering valve is less than 5%.S The engine coolant temperature is greater than
60°C (145°F).
S The mass air flow is greater than 180mg/tdc.
Action Taken When the DTC Sets
S The Malfunction Indicator Lamp (MIL) will not illumi-
nate.
S The ECM will store wnditions which were present
when the DTC was set as Failure Records data
only.
S This information will not be stored in the Freeze
Frame data.
Conditions for Clearing the MIL/DTC
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.
S Disconnecting the ECM battery feed for more than
10 seconds.
Diagnostic Aids
Check and correct any abnormal engine noise before us-
ing the diagnostic table.
Any circuitry that is suspected as causing engine noise
complaint should be thoroughly checked for the following
conditions :
S Backed–out terminals
S Improper mating
S Broken locks
S Improperly formed
S Damaged terminals
S Poor terminal–to–wire connection
S Physical damage to the wiring harness

1F – 198IENGINE CONTROLS
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0327
KNOCK SENSOR CIRCUIT FAULT (1.6L DOHC)
Circuit Description
The knock sensor (KS) system is used to detect engine
detonation, allowing the transaxle control module
(TCM)/engine control module (ECM) to retard ignition con-
trol spark timing based on the KS signal being received.
The KS produces an AC signal so that under a no knock
condition the signal on the KS circuit measures about
0.007V AC. The KS signal’s amplitude and frequency de-
pend upon the amount of knock being experienced. The
ECM contains a non–replaceable knock filter module
called a signal–to–noise enhancement filter (SNEF) mod-
ule. This filter module in the ECM determines whether
knock is occurring by comparing the signal level on the KS
circuit with the voltage level on the noise channel. The
noise channel allows the ECM to reject any false knock
signal by knowing the amount of normal engine mechani-
cal noise present. Normal engine noise varies depending
on engine speed and load. When the ECM determines that
an abnormally low noise channel voltage level is being ex-
perienced, a DTC P0327 will set.
Conditions for Setting the DTC
S The knock sensor SPI bus in failure during 10 sec-
onds.
Or
S The knock sensor voltage is less than 0.3V.
S The engine coolant temperature is greater than
60°C(145°F).
S The engine speed is greater than 1,500rpm.
S The mass air flow is higer than 180mg/tdc.
Or
S When difference between a original signal valve
and filtering valve is less than 5%.S The engine coolant temperature is greater than
60°C(145°F).
S The mass air flow is greater than 170mg/tdc.
Action Taken When the DTC Sets
S The Malfunction Indicator Lamp (MIL) will illuminate
after three consecutive trip with a fail.
S The ECM will record operating conditions at the
time the diagnostic fail. This information will be
stored in the Freeze Frame and Failure Records
buffers.
S A history DTC is stored.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.
S Disconnecting the ECM battery feed for more than
10 seconds.
Diagnostic Aids
Check and correct any abnormal engine noise before us-
ing the diagnostic table.
Any circuitry that is suspected as causing engine noise
complaint should be thoroughly checked for the following
conditions :
S Backed–out terminals
S Improper mating
S Broken locks
S Improperly formed
S Damaged terminals
S Poor terminal–to–wire connection
S Physical damage to the wiring harness

ENGINE CONTROLS 1F – 309
DAEWOO V–121 BL4
S The ECM will record operating conditions at the
time the diagnostic fail. This information will be
stored in the Freeze Frame and Failure Records
buffers.
S A history DTC is stored.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.S Disconnecting the ECM battery feed for more than
10 seconds.
Diagnostic Aids
Due to moisture associated with exhaust systems, the
EGR valve may freeze and stick in cold weather at times.
After the vehicle is brought into a warm shop for repairs,
the valve warms and the problem disappears.
By watching the Actual EGR and desired EGR positions
on a cold vehicle with a scan tool, the fault can be easily
verified. Check the Freeze Frame data to determine if the
DTC set when the vehicle was cold by viewing the Engine
Coolant Temperature (ECT).
DTC P1402 – Exhaust Gas Recirculation Blocked
StepActionValue(s)YesNo
1Perform an Euro On–Board Diagnostic (EOBD)
System Check.
Is the system check complete?–Go to Step 2Go to
”On–Board
Diagnostic Sys-
tem Check”
21. Start the engine and allow the engine to idle.
2. Install the scan tool.
3. Command the exhaust gas recirculation (EGR)
valve to the specified values.
Does the engine stall or attempt to stall?50%Go to Step 5Go to Step 3
31. Turn the ignition switch to LOCK.
2. Remove the EGR valve assembly.
3. Inspect the EGR valve, passages and pipe for
a restriction or damage and repair as neces-
sary.
Is a repair necessary?–Go to Step 5Go to Step 4
4Replace the EGR valve.
Is the replacement complete?–Go to Step 5–
51. Start the engine.
2. Disconnect the battery for the specified time.
3. Drive the vehicle to the specified value.
4. Release the throttle and allow the vehicle to
decelerate to the specified value.
Is the EGR Decel Filter Values less than the speci-
fied value?10 secnds
60mph
(27km/h)
20mph
(32km/h)
0mphGo to Step 3Go to Step 6
61. 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