DAEWOO NUBIRA 2004 Service Repair Manual

ENGINE CONTROLS 1F – 225
DAEWOO V–121 BL4
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 watchingthe Actual EGR and desired EGR positions on a cold ve-
hicle 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 P0405 – EGR Pintle Position Sensor Low Voltage
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. Turn the ignition switch ON with the engine
OFF.
2. Install the scan tool.
3. Command the Exhaust Gas Recirculation
(EGR) valve to the specified values.
Does the Actual EGR Position follow the desired
EGR position?25%, 50%
75%, 100%Go to Step 15Go to Step 3
31. Turn the ignition switch ON with the engine
OFF.
2. Disconnect the EGR valve electrical connector.
3. With a Digital Voltmeter (DVM) connected to
ground, probe the 5 volt reference circuit at
terminal 1 to the EGR valve.
Does the DVM read near the specified value?5VGo to Step 4Go to Step 5
4Jumper the 5 volt reference circuit to the signal cir-
cuit at terminals 1 and 3.
Does the actual EGR position display the specified
value ?100%Go to Step 6Go to Step 7
51. Connect the test light to B+.
2. robe the 5 volt reference circuit to the EGR
valve.
Does the test light illuminate?–Go to Step 8Go to Step 9
6Check the 5 volt reference and signal circuit for a
poor connection or proper terminal tension and re-
pair as necessary.
Is a repair necessary?–Go to Step 15Go to Step 10
71. Connect the test light to B+.
2. Probe the signal circuit at terminal 3 to the
EGR valve.
Does the test light illuminate?–Go to Step 11Go to Step 12
8Check for a short to ground in the EGR valve 5 volt
reference circuit and repair as necessary.
Is a repair necessary?–Go to Step 15Go to Step 13
9Check for an open in the EGR valve 5 volt reference
circuit and repair as necessary.
Is a repair necessary?–Go to Step 15Go to Step 14
10Replace the EGR valve.
Is the action complete?–Go to Step 15–
11Check for a short to ground in the EGR valve signal
circuit and repair as necessary.
Is a repair necessary?–Go to Step 15Go to Step 13

1F – 226IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
12Check for an open in the EGR valve signal circuit
and repair as necessary.
Is a repair necessary?–Go to Step 15Go to Step 14
131. Turn the ignition OFF.
2. Replace the Engine Control Module (ECM).
Is the action complete?–Go to Step 15–
14Check the affected circuit for a poor connection or
proper terminal at the ECM and repair as necessary.
Is a repair necessary?–Go to Step 15Go to Step 13
151. 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 specified in the supporting
text.
Does the scan tool indicate that this diagnostic ran
and passed?–Go to Step 16Go to Step 2
16Check if any additional DTCs are set.
Are any DTCs displayed that have not been diag-
nosed?–Go to
Applicable DTC
tableSystem OK

ENGINE CONTROLS 1F – 227
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0406
EGR PINTLE POSITION SENSOR HIGH VOLTAGE
Circuit Description
An Exhaust Gas Re–circulation (EGR) system is used to
lower oxides of nitrogen (NOx) emission levels caused by
high combustion temperatures. It accomplishes this by
feeding small amounts of exhaust gases back into the
combustion chamber. When the air/fuel mixture is diluted
with the exhaust gases, combustion temperatures are re-
duced.
A linear EGR valve is used on this system. The linear EGR
valve is designed to accurately supply exhaust gases to
the engine without the use of intake manifold vacuum. The
valve controls exhaust flow going into the intake manifold
from the exhaust manifold through an orifice with a engine
control module(ECM) controlled pintle. The ECM controls
the pintle position using inputs from the Throttle Position
(TP) and the Manifold Absolute Pressure (MAP) sensor.
The ECM then commands the EGR valve to operate when
necessary by controlling an ignition signal through the
ECM. This can be monitored on a scan tool as the Desired
EGR position.
The ECM monitors the results of its command through a
feedback signal. By sending a 5 volt reference and a
ground to the EGR valve, a voltage signal representing the
EGR valve pintle position is sent to the ECM. This feed-back signal can also be monitored on a scan tool and is the
actual position of the EGR pintle. The actual EGR position
should always be near the commanded or Desired EGR
position.
This Diagnostic Trouble Code(DTC) will detect an open or
short circuit.
Conditions for Setting the DTC
S EGR voltage is higher than 4.99V.
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.

1F – 228IENGINE CONTROLS
DAEWOO V–121 BL4
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 watchingthe Actual EGR and desired EGR positions on a cold ve-
hicle 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 P0406 – EGR Pintle Position Sensor High Voltage
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. Turn the ignition switch ON with the engine
OFF.
2. Install the scan tool.
3. Command the Exhaust Gas Recirculation
(EGR) valve to the specified values.
Does the Actual EGR Position follow the desired
EGR position?25%, 50%
75%, 100%Go to Step 14Go to Step 3
31. Turn the ignition switch ON with the engine
OFF.
2. Disconnect the EGR valve electrical connector.
3. With a Digital Voltmeter (DVM) connected to
ground, probe the 5 volt reference circuit at
terminal 1 to the EGR valve.
Does the DVM read near the specified value?5VGo to Step 4Go to Step 5
4Jumper the 5 volt reference circuit to the signal cir-
cuit at terminals 1 and 3.
Does the actual EGR position display the specified
value ?100%Go to Step 6Go to Step 7
51. Connect the test light to B+.
2. robe the 5 volt reference circuit to the EGR
valve.
Does the test light illuminate?–Go to Step 8Go to Step 9
6Check the 5 volt reference and signal circuit for a
poor connection or proper terminal tension and re-
pair as necessary.
Is a repair necessary?–Go to Step 14Go to Step 10
71. Connect the test light to ground.
2. Probe the signal circuit at terminal 3 to the
EGR valve.
Does the test light illuminate?–Go to Step 11Go to Step 13
8Check for a short to ground in the EGR valve 5 volt
reference circuit and repair as necessary.
Is a repair necessary?–Go to Step 14Go to Step 12
9Check for an open in the EGR valve 5 volt reference
circuit and repair as necessary.
Is a repair necessary?–Go to Step 14Go to Step 13
10Replace the EGR valve.
Is the action complete?–Go to Step 14–
11Check for a short to voltage in the EGR valve signal
circuit and repair as necessary.
Is a repair necessary?–Go to Step 14Go to Step 12

ENGINE CONTROLS 1F – 229
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
121. Turn the ignition OFF.
2. Replace the Engine Control Module (ECM).
Is the action complete?–Go to Step 14–
13Check the affected circuit for a poor connection or
proper terminal at the ECM and repair as necessary.
Is a repair necessary?–Go to Step 14Go to Step 12
141. 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 specified in the supporting
text.
Does the scan tool indicate that this diagnostic ran
and passed?–Go to Step 15Go to Step 2
15Check if any additional DTCs are set.
Are any DTCs displayed that have not been diag-
nosed?–Go to
Applicable DTC
tableSystem OK

1F – 230IENGINE CONTROLS
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0420
CATALYST LOW EFFICIENCY
Circuit Description
In order to control exhaust emissions of Hydrocarbons
(HC), Carbon Monoxide (CO) and Nitrogen Oxide (NOx),
a Three–Way Catalytic Converter (TWC) is used. The cat-
alyst within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust gas,
converting them into harmless water vapor and carbon
dioxide, it also reduces NOx, converting it into nitrogen.
The catalytic converter also has the ability to store oxygen.
The Engine Control Module (ECM) has the capability to
monitor this process using a Heated Oxygen Sensor
(HO2S) located in the exhaust stream past the TWC. The
HO2S produces an output signal which indicates the oxy-
gen storage capacity of the catalyst; this in turn indicates
the catalyst’s ability to convert exhaust emissions effec-
tively. The ECM monitors the catalyst efficiency by first al-
lowing the catalyst to heat up, waiting for a stabilization pe-
riod while the engine is idling, and then adding and
removing fuel while monitoring the reaction of the HO2S.
When the catalyst is functioning properly, the HO2S re-
sponse to the extra fuel is slow compared to the Oxygen
Sensor (O2S). When the HO2S response is close to that
of the O2S, the Oxygen storage capability or efficiency of
the catalyst is considered to be bad, and the Malfunction
Indicator Lamp (MIL) will illuminate.
Conditions for Setting the DTC
S Closed loop stoichiometry.
S Engine Coolant Temperature (ECT) is more than
75°C (167°F) . (1.4L DOHC)
S Engine Coolant Temperature (ECT) is more than
70°C (158°F) . (1.6L DOHC)
S Engine speed between 1,766rpm and 2,368rpm.
(1.4L DOHC)
S Engine speed between 1,760rpm and 2,530rpm.
(1.6L DOHC)
S Vehicle speed is between 47km/h (29.2mph) and
80km/h (49.7mph). (1.4L DOHC)
S Vehicle speed is between 60km/h (37.3mph) and
76km/h (47.2mph). (1.6L DOHC)
S The manifold absolute pressure is greater than 70
kpa. (1.4L DOHC)S The manifold absolute pressure is greater than 76
kpa. (1.6L DOHC)
S Activity of the heated oxygen sensor excited by
lambda controller stimuli higher than a threshold.
S DTC(s) P0107, P0108, P0117, P0118, P0122,
P0123, P0131, P0132, P0133, P0137, P0138,
P0140, P0141, P0171, P0172, P0300, P0336,
P0337, P0341, P0342, P0351, P0352, P0404,
P0405, P0405 and P0562 are not sets.
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
The catalyst test may abort due to a change in the engine
load. Do not change the engine load (i.e. A/C, coolant fan,
heater motor) while a catalyst test is in progress.
An intermittent problem may be caused by a poor connec-
tion, rubbed–through wire insulation, or a wire that is bro-
ken inside the insulation.
Any circuitry, that is suspected as causing the intermittent
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.

ENGINE CONTROLS 1F – 231
DAEWOO V–121 BL4
DTC P0420 – Catalyst Low Efficiency
StepActionValue(s)YesNo
1Perform an Euro On–Board Diagnostic (EOBD)
System Check.
Was the check performed?–Go to Step 2Go to
”On–Board
Diagnostic Sys-
tem Check”
21. Install a scan tool to the Data link Connector
(DLC).
2. Turn the ignition ON.
Are any component Diagnostic Trouble Codes
(DTCs) set?–Go to
Applicable DTC
tableGo to Step 3
31. Visually/physically check the following:
2. Exhaust system for a leak.
3. Heated Oxygen Sensor (HO2S).
Is a problem found?–Go to Step 4Go to Step 5
4Repair the exhaust system as needed.
Is the repair complete?–Go to Step 6–
5Replace the Three Way Catalytic Converter (TWC).
Is the repair complete?–Go 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 this DTC as specified in the supporting
text.
Does the scan tool indicate that this diagnostic has
run and passed?–Go to Step 7Go to Step 2
7Check if any additional DTCs are set.
Are any DTCs displayed that have not been diag-
nosed?–Go to
Applicable DTC
tableSystem OK

1F – 232IENGINE CONTROLS
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0444
EVAP PURGE CONTROL CIRCUIT NO SIGNAL
Circuit Description
The evaporative emission (EVAP) system includes the fol-
lowing components :
S Fuel tank.
S EVAP vent solenoid.
S Fuel tank pressure sensor.
S Fuel pipes and hoses.
S Fuel vapor lines.
S Fuel cap.
S EVAP canister.
S Purge lines.
S EVAP canister purge valve.
S EVAP service port.
The evaporative emission system is checked by applying
vacuum to the EVAP system and monitoring for a vacuum
decay. The engine control module(ECM) monitors the
vacuum level through the fuel tank pressure sensor signal.
At the appropriate time, the EVAP canister purge valve
and the EVAP vent solenoid are turned on, allowing the en-
gine to draw a small vacuum on the entire EVAP system.
After the desired vacuum level has been achieved, the
EVAP canister purge valve is turned OFF, sealing the sys-tem. If a sufficient vacuum level cannot be achieved, a
large leak is indicated. This can be caused by the following
conditions :
Missing or faulty fuel cap.
Disconnected or faulty fuel tank pressure sensor.
Disconnected, damaged, pinched, or blocked EVAP
purge line.
Disconnected or faulty EVAP canister purge valve.
Disconnected or faulty EVAP vent solenoid.
Open ignition feed circuit to the EVAP vent or purge sole-
noid.
Damaged EVAP canister.
Leaking fuel sensor assembly O–ring.
Leaking fuel tank or fuel filler beck.
Any of the above conditions can set DTC P0444.
The test is failed if the tank vacuum is less than 10 in H20
for 15 seconds and the manifold vacuum integral is greater
than 49512 (proportional to purge mass from the tank).
Conditions for Setting the DTC
S The canister purge solenoid circuit is an open con-
dition exist.

ENGINE CONTROLS 1F – 233
DAEWOO V–121 BL4
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
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 re-ported to the diagnostic executive or displayed on a scan
tool. A passing system always reports to the diagnostic
executive immediately.
Check for the following conditions :
S Missing or damaged fuel cap.
S Missing or damaged O–rings at fuel vapor and
EVAP purge line canister fittings.
S Cracked or punctured EVAP canister.
S Damaged source vacuum line, EVAP purge line,
EVAP vent hose or fuel tank vapor line.
S Poor connection at the ECM. Inspect the harness
connectors 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 Damaged harness. Inspect the wiring harness to
the EVAP vent solenoid, EVAP canister purge
valve, and the fuel tank pressure sensor for an in-
termittent open or short circuit.
S Kinked, pinched or plugged vacuum source, EVAP
purge, or fuel tank vapor line. Verify that the lines
are not restricted.
DTC P0444 – EVAP Purge Control Circuit No Signal
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. Disconnect the evaporative emission (EVAP)
canister purge valve connector.
2. Connect a test light between the EVAP canister
purge valve connector terminal 1 and battery
positive.
Is the test light ON?–Go to Step 3Go to Step 5
31. Disconnect the ECM connector.
2. Connect a test light between the ECM connec-
tor terminal 65 and ground.
Is the test light ON?–Go to Step 4Go to Step 6
41. Repair the line break in the wire between the
EVAP canister purge valve connector 2 and the
ECM connector terminal 65.
2. Clear any Diagnostic Trouble Codes (DTCs)
from the ECM.
3. Perform the diagnostic system check.
Is the repair complete?–System OK–

1F – 234IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
51. Repair the line break in the wire between the
EVAP canister purge valve connector 1 and the
main relay connector terminal 65.
2. Clear any Diagnostic Trouble Codes (DTCs)
from the ECM.
3. Perform the diagnostic system check.
Is the repair complete?–System OK–
61. Replace the ECM.
2. Perform the diagnostic system check.
Is the repair complete?–Go to Step 7–
71. 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 this DTC as specified in the supporting
text.
Does the scan tool indicate that this diagnostic has
run and passed?–Go to Step 8Go to Step 2
8Check if any additional DTCs are set.
Are any DTCs displayed that have not been diag-
nosed?–Go to
Applicable DTC
tableSystem OK