2003 DAEWOO MATIZ service

1F–286 ENGINE CONTROLS
DAEWOO M-150 BL2
SURGES OR CHUGGLES
Definition: Engine power variation under steady throttle
or cruise. Feels like the vehicle speeds up and slows
down with no change in the accelerator pedal position.Important: Make sure the driver understands A/C com-
pressor operation as described in the owner’s manual.
The speedometer reading and the speed reading on the
scan tool should be equal.
Before diagnosing the symptom, check service bulletins
for updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
Connect the scan tool to the Data Link Connector
(DLC).
Does the oxygen sensor (O2S) respond quickly to
different throttle positions?
–
Go to Step 4Go to Step 3
3
1. Check the O2S for silicone or other contaminants
from fuel or use of improper Room Temperature
Vulcanizing (RTV) sealant.
2. Replace the contaminated O2S.
Is the repair complete?
–
System OK
–
4
1. Drive the vehicle at the speed of the complaint.
2. Monitor the long term fuel trim reading using the
scan tool.
Is the long term fuel trim reading within the value
specified?
–20–25%Go to Step 7Go to Step 5
5
Is the long term fuel trim reading below the value
specified?
–20%
Go to
“Diagnostic Aids
for DTC P0172”
Go to Step 6
6
Is the long term fuel trim reading above the value
specified?
25%
Go to
“Diagnostic Aids
for DTC P0171”
–
7
Check the fuel system pressure while the condition
exists.
Is the fuel system pressure within specifications?
380 kPa
(55 psi)
Go to Step 8Go to Step 17
8Check the in-line fuel filter.
Is the filter dirty or plugged?–Go to Step 18Go to Step 9
9Perform an injector diagnosis.
Did the injector diagnosis pinpoint the problem?–Go to Step 19Go to Step 10
10
1. Check for proper ignition voltage output using a
spark tester.
2. Inspect the spark plugs for cracks, wear, improper
gap, burned electrodes, or heavy deposits.
Is the problem found?
–
Go to Step 11Go to Step 12
11
Repair or replace any ignition system components
as needed.
Is the repair complete?
–
System OK
–
12
1. Inspect the ECM grounds for being clean, tight,
and in their proper locations.
2. Inspect the vacuum lines for kinks or leaks.
Is the problem found?
–
Go to Step 13Go to Step 14

ENGINE CONTROLS 1F–291
DAEWOO M-150 BL2
Detonation/Spark Knock (Cont’d)
StepActionValue(s)YesNo
12
1. Inspect for carbon buildup inside the engine.
2. Remove the carbon with a top engine cleaner.
Follow the instructions supplied with the product.
3. Check the basic engine parts such as the
camshaft, the cylinder head, the pistons, etc. for
excessive wear.
4. Replace any excessively worn parts.
Is the procedure complete?
–
Go to Step 13
–
13
1. Check the exhaust gas recirculation valve for
proper operation.
2. Check the air intake system for proper operation.
3. Check the torque converter clutch operation and
transaxle shift points.
4. Check the service bulletins for Programmable
Read Only Memory (PROM) updates.
5. Check the cylinder compression.
6. Repair or replace any faulty components.
Are all checks and repairs complete?
–
System OK
–

1F–292 ENGINE CONTROLS
DAEWOO M-150 BL2
HESITATION, SAG, STUMBLE
Definition: Momentary lack of response as the accelera-
tor is pushed down. This can occur at any vehicle speed.
It is usually the most severe when first trying to make the
vehicle move, as from a stop. Hesitation, sag, or
stumble may cause the engine to stall if severe enough.Important: Before diagnosing this condition, check ser-
vice bulletins for PROM updates.
StepActionValue(s)YesNo
1
Were the Important Preliminary Checks performed?
–
Go to Step 2
Go to
“Important
Preliminary
Checks”
2
1. Check the fuel system pressure. If the pressure is
not within the value specified, service the fuel
system as needed.
2. Inspect the Throttle Position (TP) sensor for
binding or sticking. The TP sensor voltage should
increase at a steady rate as the throttle is moved
toward Wide Open Throttle (WOT).
Is the problem found?
380 kPa
(55 psi)
Go to Step 3Go to Step 4
3Repair or replace any components as needed.
Is the repair complete?–System OK–
4
1. Check the Manifold Absolute Pressure (MAP)
sensor response and accuracy.
2. Inspect the fuel for water contamination.
3. Check the Evaporative Emission (EVAP) Canister
Purge System for proper operation.
Is the problem found?
–
Go to Step 5Go to Step 6
5Repair or replace any components as needed.
Is the repair complete?–System OK–
6
1. Disconnect all of the fuel injector harness
connectors.
2. Connect an injector test light between the
harness terminals of each fuel injector.
3. Note the test light while cranking the engine.
Does the test light blink on all connectors?
–
Go to Step 8Go to Step 7
7
1. Repair or replace the faulty fuel injector drive
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
–
8
Measure the resistance of each fuel injector.
Is the fuel injector resistance within the value
specified (the resistance will increase slightly at
higher temperatures)?
11.6–12.4 ΩGo to Step 10Go to Step 9
9
Replace any of the fuel injectors with a resistance
that is out of specifications.
Is the repair complete?
–
System OK
–
10Perform an injector diagnosis.
Is the problem found?–Go to Step 11Go to Step 12
11Replace any restricted or leaking fuel injectors.
Is the repair complete?–System OK–
12
Check the fuel system pressure after a cold start or
during moderate or full throttle acceleration.
Is the fuel pressure within specifications?
380 kPa
(55 psi)
Go to Step 14Go to Step 13

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

1F–304 ENGINE CONTROLS
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
D102F502
D102F501
FUEL PUMP
Tools Required
DW 140–010A Fuel Pump Lock Ring Remover/Installer.
Removal Procedure
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.
1. Relieve the fuel system pressure.
Start the engine and remove the rear seat cushon
(1).
Remove the fuel pump access cover (2).
Disconnect the fuel pump assembly electrical con-
nector lock pin (3).
Disconnect the fuel pump assembly electrical con-
nector (4).
Crank the engine for an additional 10 seconds.
D102F503
2. Disconnect the fuel lines from the fuel pump.
Disconnect the fuel outlet line (1).
Disconnect the fuel tank return line (2).

ENGINE CONTROLS 1F–309
DAEWOO M-150 BL2
D102F520
5. Remove the fuel rail with the fuel injectors attached.
Remove the bolts (1).
Remove the fuel rail with the fuel injectors attached
(2).
Notice: Before removal, the fuel rail assembly may be
cleaned with a spray–type cleaner, following package in-
structions. Do not immerse the fuel rails in liquid clean-
ing solvent. Use care in removing the fuel rail assembly
to prevent damage to the electrical connectors and the
injector spray tips. Prevent dirt and other contaminants
from entering open lines and passages. Fittings should
be capped and holes plugged during service.
D102F521
6. Remove the injectors from the fuel rail.
Remove the fuel injector retainer clips (1).
Remove the fuel injectors by pulling them down
and out (2).
Discard the fuel injector O–rings (3).
Important: Different fuel injectors are calibrated for dif-
ferent flow rates. When ordering new fuel injectors, be
certain to order the identical part number that is in-
scribed on the old fuel injector.
D12F522A
18–22 Nm
Installation Procedure
1. Install in the reverse order of removal.
Important: If a fuel injector becomes separated from
the fuel rail and remains in the cylinder head, replace the
fuel injector O–ring seals and the retaining clip.
Lubricate the new fuel injector O–rings with engine
oil. Install the new O–rings on the fuel injectors.
2. Install the fuel rail retaining bolts.
Tighten
Tighten the fuel rail retaining bolts to 18–22 Nm
(13–16 lb-ft).
3. Perform a leak check of the fuel rail and the fuel injec-
tors.
MAA1F400
EVAPORATIVE EMISSION CANISTER
Removal Procedure
Caution: Canister and vacuum hoses contain fuel
vapors. Do not smoke in the area or permit an open
flame.
1. Disconnect the negative battery cable.
2. Remove the canister.
Remove the bolt (1).
Remove the nut, then remove the cover (2).

1F–314 ENGINE CONTROLS
DAEWOO M-150 BL2
D102F546
OXYGEN SENSOR (O2S1)
Removal Procedure
1. Remove the air cleaner/resonator assembly. Refer to
Section 1B, SOHC Engine Mechanical.
2. Remove the oxygen sensor.
Disconnect the oxygen sensor connector (1).
Remove the oxygen sensor (2).
Notice: The oxygen sensor uses a permanently at-
tached pigtail and connector. This pigtail should not be
removed from the oxygen sensor. Damage or removal
of the pigtail or the connector could affect proper opera-
tion of the oxygen sensor. Take care when handling the
oxygen sensor. Do not drop the oxygen sensor.
D12F547A
Installation Procedure
1. Install in the reverse order of removal.
Important: A special anti–seize compound is used on
the oxygen sensor threads. This compound consists of
a liquid graphite and glass beads. The graphite will burn
away, but the glass beads will remain, making the sen-
sor easier to remove. New or service sensors will al-
ready have the compound applied to the threads. If a
sensor is removed from any engine and if for any reason
it is to be reinstalled, the threads must have anti–seize
compound applied before reinstallation.
2. Install the oxygen sensor.
Tighten
Tighten the oxygen sensor to 35~44 Nm (26~33 lb-
ft).
MAA1F470
HEATED OXYGEN SENSOR (HO2S2)
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Remove the front center console.
3. Disconnect the HO2S2 connector.
4. Remove the front exhaust pipe. Refer to Section 1G,
Engine Exhaust.
5. Remove the HO2S2 from the front exhaust pipe.
Installation Procedure
1. Install in the reverse order of removal.

ENGINE CONTROLS 1F–315
DAEWOO M-150 BL2
Important: A special anti–seize compound is used on
the oxygen sensor threads. This compound consists of
a liquid graphite and glass beads. The graphite will burn
away, but the glass beads will remain, making the sen-
sor easier to remove. New or service sensors will al-
ready have the compound applied to the threads. If a
sensor is removed from any engine and if for any reason
it is to be reinstalled, the threads must have anti–seize
compound applied before reinstallation.
2. Install the oxygen sensor.
Tighten
Tighten the oxygen sensor to 35~44 Nm (26~33 lb-
ft).
MAA1F480
EXHAUST GAS RECIRCULATION
VA LV E
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Disconnect the electric exhaust gas recirculation
(EEGR) valve connector.
D21F008
KNOCK SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the starter. Refer to Section 1E, Engine
Electrical.
3. Disconnect the electrical connector at the knock sen-
sor (1).
D21F009
4. Remove the knock sensor.
Remove the knock sensor retaining bolt (1).
Remove the knock sensor.