2003 DAEWOO MATIZ oil pressure

ENGINE CONTROLS 1F–27
DAEWOO M-150 BL2
Engine Cranks But Will Not Run (Cont’d)
StepActionValue(s)YesNo
21
1. 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–
23
1. 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
24
1. Turn the ignition OFF.
2. Disconnect the electrical connector at the fuel
pump.
3. Connect a test light between the fuel pump
terminals 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 Step 32
25Replace the fuel pump.
Is the repair complete?–Go to Step 2–
26
Is the fuel pressure within the value specified?
380 kPa
(55 psi)
Go to Step 27Go to Step 29
27Check the fuel for contamination.
Is the fuel contaminated?–Go to Step 28Go to Step 41
28
1. Remove the contaminated fuel from the fuel tank.
2. Clean the fuel tank as needed.
Is the repair complete?
–
Go to Step 2
–
29
1. 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?
380 kPa
(55 psi)
Go to Step 2Go to Step 30
30
1. 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–
32
1. Remove the fuel pump assembly from the fuel
tank.
2. Inspect the fuel pump sender and the fuel
coupling hoses for a restriction.
3. Inspect the in-tank fuel filter for restriction.
Is the problem found?
–
Go to Step 33Go to Step 25

1F–54 ENGINE CONTROLS
DAEWOO M-150 BL2
FUEL INJECTOR BALANCE TEST
A fuel injector tester is used to energize the injector for a
precise amount of time, thus spraying a measured
amount of fuel into the intake manifold. This causes adrop in the fuel rail pressure that can be recorded and
used to compare each of the fuel injectors. All of the fuel
injectors should have the same pressure drop.
Fuel Injector Balance Test Example
Cylinder123
First Reading380 kPa
(55 psi)380 kPa
(55 psi)380 kPa
(55 psi)
Second Reading215 kPa
(31 psi)201 kPa
(29 psi)230 kPa
(33 psi)
Amount Of Drop165 kPa
(24 psi)179 kPa
(26 psi)151 kPa
(22 psi)
Average Range: 156-176 kPa
(22.5-25.5 psi)Injector OKFaulty Injector –
Too Much
Pressure DropFaulty Injector –
Too Little
Pressure Drop
Caution: The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pres-
sure before disconnecting the fuel lines.
Caution: Do not pinch or restrict fuel lines. Damage
to the lines could cause a fuel leak, resulting in pos-
sible fire or personal injury.
Notice: In order to prevent flooding of the engine, do not
perform the Injector Balance Test more than once (in-
cluding any retest on faulty fuel injectors) without run-
ning the engine.
Test
Notice: An engine cool down period of 10 minutes is
necessary in order to avoid irregular readings due to hot
soak fuel boiling.
1. Connect the fuel pressure gauge carefully to avoid
any fuel spillage.
2. The fuel pump should run about 2 seconds after the
ignition is turned to the ON position.
3. Insert a clear tube attached to the vent valve of the
fuel pressure gauge into a suitable container.
4. Bleed the air from the fuel pressure gauge and hose
until all of the air is bled from the fuel pressure gauge.
5. The ignition switch must be in the OFF position at
least 10 seconds in order to complete the electronic
control module (ECM) shutdown cycle.6. Turn the ignition ON in order to get the fuel pressure
to its maximum level.
7. Allow the fuel pressure to stabilize and then record
this initial pressure reading. Wait until there is no
movement of the needle on the fuel pressure gauge.
8. Follow the manufacturer’s instructions for the use of
the adapter harness. Energize the fuel injector test-
er once and note the fuel pressure drop at its lowest
point. Record this second reading. Subtract it from
the first reading to determine the amount of the fuel
pressure drop.
9. Disconnect the fuel injector tester from the fuel in-
jector.
10. After turning the ignition ON, in order to obtain maxi-
mum pressure once again, make a connection at
the next fuel injector. Energize the fuel injector test-
er and record the fuel pressure reading. Repeat this
procedure for all the injectors.
11. Retest any of the fuel injectors that the pressure
drop exceeds the 10 kPa (1.5 psi) specification.
12. Replace any of the fuel injectors that fail the retest.
13. If the pressure drop of all of the fuel injectors is with-
in 10 kPa (1.5 psi), then the fuel injectors are flowing
normally and no replacement should be necessary.
14. Reconnect the fuel injector harness and review the
symptom diagnostic tables.

ENGINE CONTROLS 1F–107
DAEWOO M-150 BL2
DTC P0171 – Fuel Trim System Too Lean
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. Install the scan tool to the Data Link Connector
(DLC).
2. Turn the ignition ON.
Are any component related Diagnostic Trouble
Codes (DTCs) set?
–Go to
Applicable DTC
table
Go to Step 3
3
With the engine running, operate the vehicle until the
LOOP STATUS indicates closed.
Is the Long Term Fuel Trim value below the
specified value?
–22%Go to Step 4Go to Step 5
4
1. 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 go below the
specified value while operating under the specified
conditions?
–22%Go to Step 16Go to Step 5
5
Visually/physically check the following items:

Vacuum hoses for splits, kinks and improper
connections.

Crankcase ventilation oil/air separator for proper
installation.

Exhaust system for corrosion, leaks, loose or
missing hardware.

Oxygen sensor (O2S) is installed securely and
the pigtail harness is not contacting exhaust
manifold or engine.

Fuel for excessive water, alcohol, or other
contaminants.

Engine Control Module (ECM) and sensor
grounds are clean, tight, and in their proper
locations.
Do any of the above checks isolate a condition
requiring repair?
–
Go to Step 7Go to Step 6
6
1. Disconnect the Manifold Absolute Pressure
(MAP) sensor electrical connector.
2. Operate the vehicle in Closed Loop while
monitoring the Long Term Fuel Trim value.
Is the Long Term Fuel Trim value below the
specified value?
–22%Go to Step 15Go to Step 9
7
1. Repair the malfunction found in Step 5.
2. Recheck the Long Term Fuel Trim value while
operating the engine.
Is the Long Term Fuel Trim value below the
specified value?
–22%Go to Step 8Go to Step 9
8
Lean condition is not present.
Does a driveability problem exist?
–
Go to
“Symptom
Diagnosis”
Go to Step 16

ENGINE CONTROLS 1F–319
DAEWOO M-150 BL2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Camshaft Position Sensor Bolts10–14–89–124
Engine Coolant Temperature (ECT) Sensor8–12–71–106
Crankshaft Position (CKP) Sensor Retaining Bolt5–8–44–71
Electronic Ignition (EI) System Ignition Coil Retaining
Bolts8–12–71–106
Evaporative Emission Canister Protective Cover8–71
Electric Exhaust Gas Recirculation (EEGR) Valve
Retaining Bolts20–3015–22–
Fuel Rail Retaining Bolts18–2213–16–
Fuel Tank Strap Retaining Nuts18–2213–16–
Knock Sensor Bolt15–2511–18–
Intake Air Temperature (IAT) Sensor20–3015–22–
Manifold Absolute Pressure (MAP) Sensor Retaining
Bolt8–12–71–106
Oxygen Sensor35–4426–33–
Heated Oxygen Sensor35–4426–33–
Throttle Body Retaining Bolt9–12–80–106
ECM Mounting Bolts6–8–53–71
SPECIAL TOOLS
SPECIAL TOOLS TABLE
D102F101
Scan Tool
D12F102A
DW–140–010A
Fuel Pump Lock Ring
Remover/Installer

2A–2 SUSPENSION DIAGNOSIS
DAEWOO M-150 BL2
Condition Probable Cause Correction
Car Lead/Pull
Mismatched or uneven tires.
Replace the tires.

A broken or a sagging coil spring.
Replace the coil spring.

A improperly radial tire lateral force.
Check the wheel alignment.

Switch the tire and wheel assemblies.

Replace the tires as needed.

The front–wheel alignment is
out–of–align.
Align the front wheels.

Off–center steering gear.
Reseat the pinion valve assembly.

Replace the pinion valve assembly as
needed.

Front–brake dragging.
Adjust the front brakes.
Abnormal or Excessive
Tire Wear
The front–wheel and rear–wheel
alignment is out–of–align.
Align the front and the rear wheels.

Excessive toe.
Adjust the toe.

A broken or a sagging coil spring.
Replace the coil spring.

Out–of–balance tires.
Balance the tires.

Worn strut dampeners.
Replace the strut dampeners.

A failure to rotate tires.
Rotate the tires.

Replace the tires as needed.

Overloaded vehicle.
Maintain the proper load weight.

Low tire inflation.
Inflate the tires to the proper pressure.
Scuffed Tires
Incorrect toe.
Adjust the toe.

A twisted or a bent suspension arm.
Replace the suspension arm.
Wheel Tramp
An out–of–balance tire or wheel.
Balance the tire or the wheel.

Improper strut dampener action.
Replace the strut dampeners.
Shimmy, Shake, or
An out–of–balance tire or wheel.
Balance the tire or the wheel.
Vibration
Excessive wheel hub runout.
Measure the hub flange runout.

Replace the hub as needed.

Excessive brake drum or brake rotor
imbalance.
Adjust the brakes.

Replace the brake rotor or the brake
drum as needed.

Worn tie rod ends.
Replace the tie rod ends.

Wheel trim imbalance.
Balance the wheel.

A worn ball joint.
Replace the control arm and ball joint
assembly.

Excessive wheel runout.
Measure the wheel runout.

Replace the wheel as needed.

Excessive loaded radial runout on the
tire and wheel assembly.
Match–mount the tire and wheel
assembly.

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.

4B –2 MASTER CYLINDER
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
MASTER CYLINDER
The master cylinder is designed for use in a direct–split
system. Front right brake and rear left brake are served
by the primary piston. Front left brake and rear right
brake are served by the secondary piston.
The master cylinder incorporates the functions of the
standard dual master cylinder, plus a low fluid level indi-
cator and the proportioning valve in the non–antilock
braking system.
The proportioning valves limit the outlet pressure to the
rear brakes after a predetermined master cylinder has
been reached.
Important:

Replace all the components included in the repair kits
used to service this master cylinder.

Lubricate rubber parts with clean brake fluid to ease
assembly.

Do not use lubricated shop air on brake parts, as this
may damage rubber components.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.
The torque values specified are for dry, unlubricated
fasteners.

Perform all service operations on a clean bench, free
from all traces of mineral oil.
PROPORTIONING VALVE
The proportioning valve limits the outlet pressure to the
rear brakes on the non-ABS after a predetermined mas-
ter cylinder pressure has been reached. This is used
when less rear apply force is needed to obtain optimum
braking and is usually found on disc/drum brake configu-
rations. On ABS-equipped vehicles, refer to Section 4F,
Antilock Brake System.
FLUID LEVEL SENSOR
Fluid level sensor is attached at the brake fluid reservoir.
This sensor will activate the BRAKE light if a low fluid
level condition is detected. Once the fluid level is cor-
rected, the BRAKE light will go out.

4D – 2 FRONT DISC BRAKES
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DISC BRAKE CALIPER ASSEMBLY
This caliper has a single bore and is mounted to the
steering knuckle with two mounting bolts. Hydraulic
pressure, created by applying the brake pedal, is con-
verted by the caliper to a stopping force. This force acts
equally against the piston and the bottom of the caliper
bore to move the piston outward and to slide the caliper
inward, resulting in a clamping action on the rotor. This
clamping action forces the linings against the rotor,
creating friction to stop the vehicle.
D17B001A
Important:

Replace all components included in the repair kits
used to service this caliper.

Lubricate the rubber parts with clean brake fluid to
ease assembly.

Do not use lubricated shop air on brake parts, as
damage to the rubber components may result.

If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.

Replace the pads in axle sets only.

The torque values specified are for dry, unlubricated
fasteners.

Perform the service operations on a clean bench, free
from all mineral oil materials.
CLEARANCE CALIBRATION
When the hydraulic pressure is applied to the piston, the
piston moves leftward. The piston seal, which extent
considerable pressure against the piston, moves with
cylinder.
However, as a part of the piston seal is fixed into a grove
in the cylinder shape of the seal is as shown in below
figure, distorted toward the piston moving direction.
When the pressure is taken off from the brake pedal and
the hydraulic pressure is released from the piston, a re-
storing elastic force is generated at the seal and pushes
the piston rightward and back it in original position.
As the pads wear away and the clearance between rotor
and pads becomes larger, the piston moves larger.
The seal then could change in shape further, but since
end of the seal is fixed into the groove in the cylinder, the
distortion is limited to the same amount as previously
described.
The piston moves further to cover the distance of clear-
ance. As the piston returns by the same distance and
the rubber seal recovers its original shape, the clear-
ance between the rotor and pads is maintained in origi-
nal condition.
1. Piston
2. Piston Seal
3. Pads
a. Clearance
D107B002